Hybrid digital complete prosthesis in a high-demand clinic: case report, challenges and perspectives

Abstract

Advances in digital technologies, such as CAD/CAM systems and 3D printing, have expanded the possibilities for complete denture fabrication, with potential improvements in accuracy, predictability, and reduced clinical time, particularly in edentulous patients. This study reports a clinical case of maxillary complete denture rehabilitation using a hybrid workflow that integrates conventional and digital techniques. An edentulous patient was rehabilitated with a 3D-printed maxillary complete denture, using the patient’s pre-existing denture as a custom impression tray and esthetic and functional reference, thereby preserving previously established occlusal relationships. The protocol included scanning of the functionalized denture, denture fabrication by 3D printing, a clinical try-in for functional and esthetic adjustments, and final delivery after finishing and polishing, with treatment completed within 14 days. The denture demonstrated clinically satisfactory retention, adequate adaptation, and favorable esthetics, in addition to a reduced number of clinical appointments and a high level of patient satisfaction, particularly regarding denture stability and shortened treatment time. It can be concluded that the hybrid workflow proved to be efficient and clinically feasible; however, its predictability depends on professional experience and clinical–laboratory integration, making it, under current clinical conditions, a safe and predictable approach for complete denture fabrication.