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Hybrid Digital Workflow for Accurate Distal Extension Reproduction in Free-End Removable Dental Prosthesis: A
Thais Marques Simek Vega Gonçalves1, Zuila Maria Lobato Wanghon1, Liliane da Rocha Bonatto Drummond1
1Department of Dentistry, Federal University of Santa Catarina (UFSC), Florianópolis 88040-900, SC, Brazil.
Dentistry Journal
|March 27, 2026
Summary
A new hybrid digital workflow accurately fabricates distal-extension removable dental prostheses (RDPs) by combining plaster-cast and intraoral scanning. This method improves denture accuracy and stability while reducing clinical time and costs.
Area of Science:
- Dental prosthetics
- Digital dentistry
- CAD/CAM technology
Background:
- Fabricating distal-extension removable dental prostheses (RDPs) presents challenges in accurately reproducing mobile mucosa in free-end saddles.
- Denture base accuracy and stability are critical for successful RDP outcomes.
Purpose of the Study:
- To introduce an innovative hybrid digital workflow integrating diagnostic plaster-cast scanning and intraoral scanning.
- To produce an accurate 3D-printed model for fabricating RDPs.
Main Methods:
- The workflow combines conventional impression-making with digital scanning of diagnostic casts and intraoral scanning of prepared teeth.
- A refined virtual model is created by merging digitalized casts and intraoral scans for CAD-based metal framework design.
- The metal framework is digitally designed, 3D-printed for verification, cast, and incorporated into standard RDP fabrication steps.
Main Results:
- The hybrid workflow achieved highly accurate reproduction of the distal extension region, surpassing models from intraoral scanning alone.
- Digital capture of mobile mucosa morphology eliminated the need for the traditional altered-cast technique.
- This approach reduced clinical time, technical sensitivity, and material costs.
Conclusions:
- The proposed digital protocol enhances denture base accuracy and adaptation for free-end RDPs.
- It promotes more uniform occlusal load distribution, improving prosthesis stability and long-term outcomes.
- This streamlined and reproducible workflow represents a clinically relevant advancement in digital dentistry.
