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Fabrication of a Maxillary Prosthesis for a Flap-Reconstructed Maxillary Defect Using a 3D-Printed Occlusal Record

Mariko Hattori¹, Manjin Zhang², Yuka Sumita³

¹Department of Advanced Prosthodontics, Institute of Science Tokyo, Tokyo, JPN.

|July 12, 2026

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This study introduces a simplified digital method for fabricating maxillary prostheses using 3D scans of existing prostheses. This approach enhances accuracy and reduces adjustments for better patient outcomes.

Area of Science:

Dental Prosthetics
Digital Dentistry
Maxillofacial Reconstruction

Background:

Fabricating maxillary prostheses for patients with flap-reconstructed defects presents significant clinical and technical challenges.
Conventional impression techniques are often hazardous and necessitate multiple adjustments, increasing patient discomfort and treatment time.
Existing digital workflows can be complex and require advanced technical expertise.

Purpose of the Study:

To present a simplified digital workflow for fabricating maxillary prostheses.
To reduce the clinical burden and risks associated with conventional impression techniques.
To improve the fit and reduce post-delivery adjustments of maxillary prostheses.

Main Methods:

A 3D intraoral scan of a previously relined and adjusted prosthesis was acquired.

Keywords:

complete edentulous digital dentistry digital workflow flap reconstruction maxillectomy maxillofacial prosthesis obturator

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The 3D scan data were utilized to print an occlusal record base.

Jaw relations were recorded, teeth were arranged, and a functional impression was taken during the try-in stage before final prosthesis fabrication.

Main Results:

The digital workflow using a 3D printed record base demonstrated accurate adaptation.
This method minimized clinical risks inherent in conventional impression making.
Incorporating a functional impression during try-in improved prosthesis fit and reduced the need for post-delivery adjustments.

Conclusions:

The described digital approach offers a practical and simplified method for maxillary prosthesis fabrication.
Reusing existing prosthesis morphology streamlines digital processing and reduces clinical complexity.
This technique is particularly beneficial in settings with limited access to advanced technical support.