Optimizing Complete Denture Fabrication With a Hybrid Analog–Digital Workflow: A Case Report

Complete dentures often present significant challenges regarding precision and stability. With advances in 3D printing technologies and combined analog–digital workflows, new approaches have been developed that optimize both clinical efficiency and functional and aesthetic outcomes. This case report presents the treatment of a 70-year-old completely edentulous patient that was managed using an analog–digital workflow, with the prosthesis fabricated through 3D printing. Preliminary impressions were taken using alginate for the lower jaw and digital scanning for the upper jaw. Base plates were designed and 3D-printed, over which wax rims were placed for the determination of vertical dimension and centric relation. Subsequently, border molding was performed with the base, and a functional impression was taken using light body silicone. After obtaining the final impressions, a prototype printed in biocompatible resin was tested to evaluate occlusal and esthetic adjustments. Finally, the definitive prosthesis was 3D-printed using a high-precision printer. The process significantly reduced both clinical and laboratory time, with increased precision in denture adaptation and occlusion. The patient expressed excellent satisfaction with the final result, reporting improved comfort, functionality, and aesthetics compared to previous experiences with conventional dentures. This treatment approach, by integrating analog techniques with digital technologies, optimized both treatment efficiency and predictability.