A Novel Technique for Designing and Manufacturing Complete Mandibular Dentures with Resilient Linings Using Additive...

Area of Science:

• Dentistry
• Prosthodontics
• Biomaterials Engineering

Background:

• Traditional denture relining can be problematic and time-consuming.
• Existing digital workflows in prosthodontics are continuously evolving.

Purpose of the Study:

• To present a fully digital protocol for designing, fabricating, and assembling a mandibular denture with a resilient liner.
• To leverage Computer-Aided Design/Computer-Aided Manufacturing (CAD/CAM) and 3D printing for denture fabrication.
• To offer a novel solution for denture relining compatible with additive manufacturing.

Main Methods:

• Utilized CAD/CAM software to design denture teeth, base, and a 2 mm resilient liner with positioning points.
• Created a T-shaped key and an alignment jig for precise component assembly and stable occlusion.
• Employed 3D printing for additive manufacturing of all components.
• Assembled the denture using photopolymer, followed by trimming and polishing.

Main Results:

• Successfully designed and fabricated a mandibular denture with an integrated resilient liner using a digital workflow.
• The alignment jig ensured ease of assembly and maintained stable occlusion.
• Demonstrated the feasibility of using diverse methacrylate formulations with additive manufacturing for denture components.

Conclusions:

• The developed digital technique offers a reproducible and efficient method for fabricating mandibular dentures with resilient liners.
• This additive manufacturing approach presents a viable alternative to conventional relining procedures.
• The protocol advances the integration of digital workflows in removable prosthodontics.