A digital duplicating obturator with 3D printing technology

Obturators are vital for restoring function and appearance in patients with maxillofacial defects, though traditional fabrication involves multiple clinical visits and extended production time. This technique report details a digital approach using computer-aided design/manufacturing (CAD/CAM) and 3D printing to duplicate an obturator for a 74-year-old patient with maxillary bone necrosis. By using a chairside intraoral scanner, we obtained a digital model of the existing obturator, avoiding traditional impression-taking and reducing procedural discomfort. A 3D-printed obturator was fabricated, adjusted with a tissue conditioner, and refined to ensure optimal fit. Laboratory processes included using specialized materials and retention techniques. The digital workflow minimized patient visits and improved comfort, underscoring CAD/CAM and 3D printing's potential to enhance clinical efficiency and quality of life for patients requiring complex prosthetic rehabilitation. This approach highlights the practical benefits of integrating digital and analog methods in maxillofacial prosthetics. (Int J Maxillofac Prosthetics 2024;7:16-19)