Conventional vs. 3D-printed complete dentures in an irradiated edentulous patient: a case report with clinical comparison.

Background and aims: In recent years, digital workflows for the fabrication of complete dentures have been developed, enabling patients to benefit from reduced chairside time, fewer clinical sessions, and improved comfort compared to conventional techniques. Additive manufacturing through 3D printing has emerged as a viable alternative to heat-cured acrylics, offering enhanced adaptation, esthetics, and clinical efficiency. The objective of this clinical case report is to compare two pairs of newly fabricated complete dentures: one produced through a conventional manufacturing process and the other through additive manufacturing (3D printing). The comparison focused on denture retention and peripheral seal, manufacturing time, and esthetic outcomes. Case presentation: A fully edentulous male patient with a history of head and neck cancer presented for prosthetic rehabilitation. Clinical challenges included advanced mandibular ridge atrophy, post-radiotherapy hyposalivation, and recurrent prosthetic stomatitis. The existing prosthesis was repurposed as an individual tray, and functional impressions were recorded using a closed-mouth technique with addition-cured silicone material. Two sets of dentures were fabricated: a pair of conventional heat-cured acrylic dentures and a pair of digitally designed and 3D-printed dentures (maxillary and mandibular). A comparative evaluation was performed focusing on clinical adaptation, retention, esthetics, and fabrication efficiency.The digitally produced complete dentures fabricated by 3D printing demonstrated comparable fit, retention, and suction to those achieved with conventional heat-cured acrylic dentures. Despite the patient's advanced mandibular ridge atrophy and hyposalivation, both sets of dentures provided functional adaptation and adequate stability. However, the additive manufacturing process offered less fabrication time and required fewer clinical visits. Esthetically, the printed dentures were rated as satisfactory by both the patient and the clinician, matching the outcome of the conventional pair. Conclusions: These findings suggest that the digital workflow of complete dentures might be considered a promising alternative for prosthetic rehabilitation, particularly in medically complex geriatric patients. Further clinical studies are warranted to confirm long-term outcomes.