A hybrid digital-analog workflow for single-session fabrication of bar-retained overdentures from an interim denture

To introduce a streamlined hybrid digital–analog workflow that allows the conversion of a validated interim denture into a definitive bar-retained overdenture in a single clinical session. A maxillary edentulous patient rehabilitated with four anterior implants was treated using a workflow that combined extraoral and intraoral scanning, digital file alignment, and 3D printing of a perforated duplicate denture. The duplicate, fabricated from transparent biocompatible resin, was used intraorally to pick up provisional cylinders in maximum intercuspation, thereby transferring implant positions and functional parameters directly to the laboratory. The duplicate precisely replicated the intaglio and occlusal surfaces of the interim denture, enabling accurate transfer of implant positions. The final overdenture exhibited passive fit, satisfactory aesthetics, and stable function. The entire workflow was completed in approximately 90 min during a single clinical session, requiring only intraoral scanning and one 3D-printing step, while keeping the patient rehabilitated throughout the process. This clinical technique report introduces a hybrid digital-analog workflow that integrates widely available digital tools with conventional procedures to streamline the fabrication of bar-retained overdentures. The workflow reduces the number of appointments, preserves validated esthetic and occlusal parameters, and offers a practical, cost-effective solution for clinicians without advanced digital infrastructure. • Hybrid digital–analog workflow enables single-session bar-retained overdentures. • Validated interim denture serves as reference for esthetics, occlusion, and function. • Protocol is reproducible with different 3D mesh-editing software, not software-specific. • Reduces appointments, preserves patient comfort, and lowers clinical complexity.