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Revolutionizing Prosthetic Dentistry: The Benefits of Digital Denture Workflows

mm Written by Andrew Sedler / March 8, 2025

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The Benefits of Digital Denture Workflows

With the dental industry embracing modern technology, adopting a digital denture workflow is crucial to providing patients with efficient, accurate, and high-quality dental care. This method utilizes digital scanning, computer-aided design, and 3D printing or milling, replacing the traditional labor-intensive process with a more streamlined, precise, and predictable one.

By implementing a digital workflow, dentists can provide enhanced patient comfort, greater satisfaction, faster turnaround times, and a higher level of precision and customization. With this advancement, dental professionals are addressing the increasing demands of modern patients and greatly enhancing their practice’s capabilities and competitive advantage.

The following case study demonstrates the effective implementation and impact of a digital denture workflow in a modern dental practice. We were thrilled to collaborate with Dr. Katherine Diep on this project.

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Patient Situation

In 2010, a patient suffering from complete tooth loss in both the upper (maxilla) and lower (mandible) jaws needed extensive prosthodontic treatment. A complete denture was created and fitted for her upper jaw. In contrast, her lower jaw was treated with an overdenture supported by locators, incorporating implants placed at the sites of teeth #22 and #27.

Fast-forward to a more recent visit. Her denture teeth exhibited apparent signs of wear, and she had unfortunately experienced implant failure at tooth site #27, prompting the need for a new prosthesis. The silver lining, however, was her satisfaction with her existing denture. This presented the case with an invaluable guide for the design of her new prosthesis.

Case Study of a Digital Denture Workflow

The Benefits of Digital Denture Workflows - Burbank Dental Lab - Burbank, CA

Recognizing the patient’s comfort and familiarity with the tooth positioning of her existing dentures, Dr. Diep decided to employ a digital denture workflow. This innovative approach ensured that the new set would meticulously echo the contours of the old prosthesis, aligning with the patient’s preferences. It also provided the capacity to readily remill the prosthesis if a replacement should ever become necessary in the future.

The comprehensive steps involved in actualizing the final prosthesis through this digital denture workflow enhanced precision, ensured patient satisfaction, and streamlined overall process efficiency. These steps, detailed in the subsequent sections, demonstrate the substantial benefits of integrating a digital denture workflow into a modern dental practice.

CTCT Scan - The Benefits of Digital Denture Workflows - Burbank Dental Lab - Burbank, CA
  1. Dr. Diep began this case by taking a CBCT scan of the patient’s existing dentures.
  2. Exocad was used to convert the DICOM (Digital Imaging and Communications in Medicine) file into an STL (stereolithography) file.
  3. This data was used to print a duplicate of the denture using a clear resin.
  4. This was then used to create a custom tray to make a wash impression of the patient’s residual ridges.
  5. A centric relation record was then taken at an increased VDO to restore the ~2mm that had been lost over time.
  6. The above data was sent to the dental lab for printing a try-in based on the existing prosthesis.
  7. The prosthesis was then tried in and evaluated by both Dr. Diep and the patient.
  8. Since the try-in was successful, Burbank Dental Lab milled the final prosthesis.
CTCT Scan - The Benefits of Digital Denture Workflows - Burbank Dental Lab - Burbank, CA
CTCT Scan - The Benefits of Digital Denture Workflows - Burbank Dental Lab - Burbank, CA
How To Avoid A Dental Prosthesis Remake Due To Fit - by Vincent Nalbandian, Implant Department Manager

The Benefits of a Digital Denture Workflow

  • Efficiency: The traditional method of creating dentures requires considerable time and effort due to its multistep process. Nonetheless, this process can be substantially simplified by implementing a digital workflow. The scanning process can be completed expeditiously, and digital models can be produced and modified promptly. Finally, the finished dentures can be milled or printed, and it is worth noting that this entire process can be completed within a few hours.
  • Accuracy and Precision: Advanced software is utilized to create digital dentures, guaranteeing an elevated level of accuracy and enabling minor modifications that may be arduous to accomplish manually. As a consequence, patients can enjoy a more precise and pleasant fit.
  • Predictability: Digital dentures provide the advantage of visualizing the final product upfront before the fabrication process. This allows for the opportunity to review and make any necessary alterations to the design before proceeding with the creation of the dentures. With this, one can accurately anticipate the end result, saving time and resources.
  • Consistency: The digital workflow process adheres to a standardized approach, resulting in an output of consistently high quality. This is in contrast to manual methods, which can vary depending on the expertise and skill level of the individual performing the work. Digital methods ensure that every denture is produced to the same exceptional standard.
  • Data Storage and Reproduction: A digital model of a patient’s mouth can be created and saved indefinitely. This feature allows for the convenient reproduction of the denture in case of loss or damage without requiring the patient to return for a new set of impressions. Furthermore, it can aid in monitoring any changes in the patient’s oral condition over time.
  • Patient Satisfaction: Patients often appreciate the speed and convenience of digital dentures. The ability to visualize the final result before it is created can also lead to higher patient satisfaction. The precise fit of digital dentures can also contribute to increased comfort and functionality, improving the overall patient experience.
  • Competitive Advantage: Embracing digital dentistry can give practices an edge over those that only offer traditional methods. By providing faster, more precise, and predictable results, you can attract more patients and enhance your practice’s reputation for innovative care.
How To Avoid A Dental Prosthesis Remake Due To Fit - by Vincent Nalbandian, Implant Department Manager

Integrating digital technology in dentistry is a learning process, and mastering it requires time, patience, and training. However, with the multitude of benefits it offers, it is indeed a worthy investment for the future of any dental practice.

The advent of digital denture workflows presents a transformative shift in dental prosthetics, promising enhanced precision, efficiency, and patient satisfaction. In addition to capturing and reproducing individual dental profiles accurately, digital workflows offer long-term benefits as well. Contact Burbank Dental Lab for help on your next removable case.

We thank Dr. Katherine Diep for her valuable insights and contributions to this article.

Dr. Katherine Diep

Dr. Katherine Diep

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STEP 1

Burbank Dental Lab implant scan specialist provides the special scan bodies for insertion in the patient’s newly placed implant sites.

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Scan Bodies are removed and special healing abutments are placed on the implant sites. Soft tissue can now be scanned with an intra-oral scanner.

STEP 3

The data from both scans are then sent to the laboratory. The ICam4d data and soft tissue scans are aligned to become a high-precision dental model.

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