Use of Digital Technology to Fabricate a Metal-Based Maxillofacial Prosthesis for Mandibular Defects

It is difficult to make conventional impressions for maxillofacial prostheses in patients with complicated anatomical structures. In addition, even after fabrication, multiple adjustments are usually needed due to its complex morphology. This article describes a combined conventional and digital workflow for fabricating maxillofacial prostheses. An intraoral scanner was used to obtain three-dimensional (3D) data on the interim prosthesis and oral cavity of the patient with a mandibular defect. The surface data of the interim prosthesis was 3D printed with acrylic to fabricate an occlusal record base. A metal framework was fabricated using a combination of digital methods for design and wax pattern fabrication and conventional methods for metal casting. An acceptable fit and a satisfactory clinical outcome were demonstrated by the digitally fabricated new prosthesis. Intraoral scanning and 3D printing are useful alternatives to conventional impression and casting techniques for fabricating prostheses for maxillofacial patients.