A Novel Technique for Designing and Manufacturing Complete Mandibular Dentures with Resilient Linings Using Additive Manufacturing

This dental technique presents a fully digital protocol for designing, fabricating, and assembling a mandibular denture with a resilient liner using readily available CAD/CAM software and 3D printing technologies. The digital method allowed denture teeth, denture base, and resilient liner as components to be designed and exported as separate files for additive manufacturing. It involves importing a cast into CAD software to create a T-shaped key, designing a 2 mm resilient liner with six positioning points, generating a mandibular denture base and alignment jig, 3D printing all components, post-processing, assembling with photopolymer, and final trimming and polishing. The additional cast and alignment jig design demonstrated ensured ease of component assembly and stable occlusion. The development of this novel technique using additive manufacturing advances the applications of the digital workflow in removable prosthodontics. The method is proposed as a potential solution to the problems associated with the traditional relining process, with a particular emphasis on its compatibility with additive manufacturing processes that utilise diverse methacrylate formulations, in contrast to conventional polymethylmethacrylates.