Digital dentures represent a modern advancement in prosthetic dentistry, utilizing computer technology to create tooth replacements with a high degree of precision. This technology moves away from manual, multi-step processes toward a streamlined, data-driven method. The fabrication relies heavily on Computer-Aided Design (CAD) and Computer-Aided Manufacturing (CAM) systems, which fundamentally change how these devices are conceived and produced.
Defining Digital Dentures
A digital denture is a dental prosthesis designed and manufactured entirely through a digital workflow, distinguishing it from traditional manual fabrication. The process bypasses the need for physical impressions, plaster models, and the manual assembly of the denture components. Instead, the patient’s oral anatomy is captured as a three-dimensional dataset, which serves as the blueprint for virtual planning and adjustments.
CAD software allows a technician to virtually place teeth and contour the denture base with mathematical accuracy. Once the design is finalized, CAM translates the digital file into a physical denture using specialized machinery.
The Digital Workflow
The process begins with the acquisition of patient data, typically involving an intraoral scanner used in the dentist’s office. This device captures a precise, three-dimensional image of the patient’s gums, residual ridges, and remaining teeth, replacing traditional putty impressions. If an intraoral scan is not feasible, conventional impressions or existing dentures can be scanned using a desktop scanner to convert the physical data into a digital format.
Once the digital scan and bite registration records are complete, the information is sent to a dental laboratory for the design phase. Technicians use specialized CAD software to design the denture base and the arrangement of the prosthetic teeth. This virtual environment allows for precise calibration of the bite, or vertical dimension of occlusion, before manufacturing begins.
The final step is physical fabrication, achieved through two primary CAM methods: subtractive milling or additive 3D printing. Subtractive milling involves carving the denture base and teeth from pre-manufactured, highly-cured polymer blocks. Additive manufacturing, or 3D printing, builds the denture layer by layer using light-cured resin.
Key Differences from Traditional Dentures
The shift to a digital process results in several tangible benefits compared to conventional counterparts. One difference is the precision of the fit, as digital mapping minimizes the material distortion inherent in traditional methods. Conventional dentures are fabricated using a heat-polymerization process, which can introduce dimensional changes in the acrylic resin as it cures. Digital dentures, particularly those that are milled, start with perfectly cured material, leading to a more accurate fit and improved retention.
Milled digital dentures are typically made from a dense, homogenous polymethyl methacrylate (PMMA) resin. This material is stronger and less porous than the acrylics used in conventional dentures. The increased density makes the base less prone to absorbing liquids and staining, promoting better hygiene and durability. Furthermore, the digital file acts as a permanent record, allowing for the rapid creation of an exact duplicate should the original denture be lost or damaged.
This streamlined workflow also reduces the number of clinical appointments required. Traditional fabrication often necessitates multiple try-in and adjustment visits, which can be time-consuming. The accuracy of the digital process reduces the required appointments to as few as two or three, saving the patient time.
Types and Applications
Digital technology is versatile and can be applied to various prosthetic needs beyond replacing a full set of teeth. The most common application is the fabrication of complete or full arch dentures for patients missing all teeth in one or both jaws. The digital design software enables the creation of highly customized full prostheses with predictable aesthetics and function.
The technology is also used for partial dentures, which replace only a few missing teeth while fitting around the remaining natural ones. For patients receiving dental implants, the digital workflow creates implant-supported overdentures, which snap onto the implants for superior stability and retention. Additionally, digital methods are employed for immediate dentures, prepared before tooth extractions and placed immediately afterward, allowing the patient to maintain function and appearance during the healing phase.