Digital dentures in exocad: the Full Denture module workflow
How digital dentures are designed in the exocad Full Denture module: model analysis, tooth setup, denture base, and milled, printed or monolithic output.
Complete dentures were one of the last indications to move into CAD. A digital denture design can be saved, reproduced and adjusted at any time, and production can be milled, printed or a combination of both. In exocad the work happens in the Full Denture module, which guides the technician from model analysis to production files. This post follows that workflow and the records it depends on.
Records needed for digital dentures
The design starts from scans of the edentulous arches, taken from impressions or directly, with the functional borders captured. The jaw relation comes from bite rims scanned together, or from an existing denture scanned in occlusion. Aesthetic references such as midline, smile line, lip support and occlusal plane guide the setup, and photos help a lot. The order also needs the tooth size, shape and library, and the production route, because milled, printed and monolithic try-in designs are prepared differently.
When dentures need extra try-ins, the cause is usually a missing or unverified jaw relation, or missing aesthetic references.
The Full Denture design sequence
Model analysis
Anatomical landmarks are marked on the models, for example the alveolar ridge, reference points in the posterior areas and the midline. According to exocad, the results of this analysis drive the automatic full-arch tooth setup proposal.
Tooth setup
The module proposes a setup from the analysis and the chosen tooth library. The technician then adjusts position, inclination and occlusion. Libraries designed for digital workflows, with predefined contact points, make the automatic occlusion much faster to refine.
For balanced occlusion concepts, check in the virtual articulator how the setup behaves in movement (see virtual articulator and jaw motion).
Denture base
Next come the borders, base thickness, palatal shape and gingiva modeling. Gingival characterization and surface texture make a visible difference to how natural the denture looks.
Production output
The module supports several production routes. In two-step milling, base and teeth are milled separately and then joined. With a printed base, the teeth are prefabricated or printed and bonded into it. A monolithic printed denture has teeth and base in a single print, which is often used for try-ins. The right choice depends on the equipment available and on the validated indications of the materials.
The try-in
A monolithic printed try-in is inexpensive and quick to make, and it is geometrically identical to the final design. The patient tests aesthetics, phonetics and comfort, and the changes go back into the saved design file. On a wax try-in the same changes would have to be transferred by hand.
Why labs move dentures into CAD
The saved design is a permanent record, so a lost or broken denture can be produced again from the file. Setups can be copied and refined for the next denture. When the records are complete from the start, the number of appointments usually goes down, and milling or validated printing gives a consistent production quality.
Where digital denture cases go wrong
Borders that are incomplete in the scan lead to a base that does not seal. A jaw relation that was never verified produces a setup that looks right on screen and is wrong in the mouth. Skipping the try-in to save a week tends to cost more at delivery. And a design prepared for one production route does not simply transfer to another, so decide the route before designing.
For the models that often accompany denture work, see 3D printed dental models with Model Creator.
Frequently asked questions
Can dentures be fully 3D printed?
The exocad Full Denture module supports printed denture bases with separate teeth and monolithic printed dentures, which are often used as try-ins. Definitive use depends on the validated material and printer workflow.
Which records are needed for a digital denture?
Scans of the edentulous arches or of the impressions, the jaw relation (scanned bite rims or an existing denture in occlusion), and aesthetic references such as midline, smile line and lip support.
What are denture tooth libraries?
Digital versions of denture teeth. Libraries built for digital workflows have predefined contacts, which speed up the automatic setup and occlusion.
Can an existing denture be copied digitally?
Yes. A scan of a well-accepted existing denture is a good starting point for the new setup, which is then corrected where needed.