3D Printing in custom tray design for complete dentures in patients with flabby tissues

Flabby ridge tissues present a significant challenge in complete denture fabrication because their mobility compromises support, stability, and retention. Conventional techniques such as the open window, selective pressure, or mucostatic methods attempt to control tissue displacement but often rely heavily on operator skill and may result in unpredictable outcomes.

This case report describes a novel digital workflow for managing flabby ridge tissues during complete denture fabrication. An intraoral scan and design software were used to identify and duplicate the flabby ridge area. A 1.5 mm offset was digitally applied to provide controlled relief in the custom tray. The tray was manufactured through 3D printing, and clinical procedures included closed-mouth border molding followed by a functional definitive impression. This approach allowed the impression to be taken under occlusal load, reproducing the functional adaptation of the tissues.

The integration of digitally controlled relief with a closed-mouth mucocompressive technique provided accurate registration of the denture-bearing area while minimizing tissue distortion. The final prosthesis demonstrated satisfactory retention, stability, and esthetics. The patient reported comfort and functional efficiency, particularly during mastication.

This case demonstrates the feasibility and advantages of combining digital design and 3D printing of custom trays with a closed-mouth impression technique in patients with flabby ridge tissues. The workflow offers a reproducible, minimally invasive, and time-efficient alternative to conventional approaches, highlighting the value of 3D printing as a tool to enhance precision and standardization in complete denture fabrication.