Digital Fabrication Of Hollow Obturators For Maxillary Defects

Extensive maxillary defects challenge interim obturation due to labor-intensive traditional methods for required hollow prosthesis. This case presents a digital workflow enabling same-day delivery of closed hollow interim obturators. A 55-year-old patient scheduled for maxillectomy (squamous cell carcinoma) underwent preoperative intraoral scanning (Aoralscan 3, Shining 3D) to design a surgical obturator with cones for coronal cover positioning. The obturator was additive manufactured (Pro95 printer, SprintRay; Dentca Denture Base II/Teeth, Dentca) and seated intraoperatively. Post-surgery, it served as a custom tray for defect impressions. A coronal cover was digitally designed via "Offset," "Boolean subtraction," and "Shell" (Geomagic Wrap, 3D Systems), printed (Pro95), and bonded to the obturator using the denture base resin . Total chairside time was <2 hours. The technique eliminated manual hollowing and casts, reducing prosthesis weight by 46.97% versus solid designs. Precise 2-mm coronal cover thickness ensured structural integrity and hermeticity, with no leakage at 3-month follow-up. Single-visit fabrication (1-hour printing/assembly) minimized clinical appointments, while high trueness reduced chairside adjustments. This digital approach streamlines rehabilitation, enhancing retention, comfort, and function for extensive maxillary defects. It demonstrates the viability of additive manufacturing in time-sensitive prosthetic care.