Digital Fabrication Of Hollow Obturators For Maxillary Defects

Introduction: Extensive maxillary defects challenge interim obturation due to labor-intensive traditional methods for required hollow prosthesis. This case presents a digital workflow enabling same-day delivery of closed hollow interim obturators. Case description: A 55-year-old patient scheduled for maxillectomy (squamous cell carcinoma) underwent preoperative intraoral scanning (Aoralscan 3, Shining 3D) to design a surgical obturator with cones for coronal cover positioning. The obturator was additive manufactured (Pro95 printer, SprintRay; Dentca Denture Base II/Teeth, Dentca) and seated intraoperatively. Post-surgery, it served as a custom tray for defect impressions. A coronal cover was digitally designed via ''Offset,'' ''Boolean subtraction,'' and ''Shell'' (Geomagic Wrap, 3D Systems), printed (Pro95), and bonded to the obturator using the denture base resin . Total chairside time was <2 hours. Discussion: The technique eliminated manual hollowing and casts, reducing prosthesis weight by 46.97% versus solid designs. Precise 2-mm coronal cover thickness ensured structural integrity and hermeticity, with no leakage at 3-month follow-up. Single-visit fabrication (1-hour printing/assembly) minimized clinical appointments, while high trueness reduced chairside adjustments. Conclusion/clinical significance: This digital approach streamlines rehabilitation, enhancing retention, comfort, and function for extensive maxillary defects. It demonstrates the viability of additive manufacturing in time-sensitive prosthetic care.