To report a case of fabrication of duplicate dentures using digital technique for an edentulous patient, and to investigate the workflow and clinical efficacy of this method.

A fifty-four-year old edentulous female with complete dentures which had been worn for seven years and suffered from fissures in the maxilla denture base was recruited. The patient visited the Department of Prosthodontics, Peking University School and Hospital of Stomatology in August 2020. Intraoral examination revealed slightly absorbed residual alveolar ridge and epulis fissuratum at the vestibular sulcus of upper right anterior teeth. After tissue conditioning, a model scanner (3-Shape) was used to obtain the complete surface morphological information of the existing dentures. The generated STL file from this technique represented a digital duplicate of the scanned dentures. A set of wax-up duplicate dentures were milled by a five-axis CNC equipment. The occlusal relationship and fullness were re-determined after wax-up try-in. The initial models reproduced with silicone rubber and jaw relationship were transferred to an articulator. After wax teeth replaced with artificial teeth, the occlusal relationship was verified. After border molding, the wax-up was used to take a close-mouth impression. The final models were poured using plater. The duplicate dentures were completed after installing the plastic to the press box and heating. The patient′s satisfaction was measured using the visual analogue scale (VAS) after denture delivery.

The restoration treatment was completed. The duplicate dentures with good retention and stability, and proper extension of the base edge got good aesthetics and high patient′s satisfaction. Occlusal balance was achieved by a bit of adjustment. Follow-up visit, the patient had no tenderness, good chewing function and good aesthetic effect. The VAS scores of this patient on the digital duplicate dentures showed high satisfaction. Each score of general satisfaction, cleaning, ability to speak, comfort, aesthetics and ability to chew up was higher than nighty-seven. The other two aspects of retention and stability got not less than 96 scores.

The digital technology could be used to fabricate duplicate dentures for edentulous patient who wore complete dentures for a long time without discomfort to reduce clinical visits, simplify the procedures and improve clinical outcomes and patient′s satisfaction.