Manufacturing Method For Overlaid Prosthesis Structured By Teeth

Abstract

The rehabilitation of patients with severely worn or partially edentulous dentition requires restorative solutions that balance structural integrity with aesthetic requirements.1 Overlaid prostheses (overlay dentures) offer a conservative alternative to traditional extractions or high-risk implants, yet their success depends heavily on the precision of the manufacturing process.

Objective: This study describes an advanced manufacturing method for overlaid prosthesis structures, focusing on the integration of digital workflows and material science to enhance the fit, durability, and functional occlusion of the final restoration.

Methods: The manufacturing protocol involves a multi-stage approach:

Utilizing intraoral scanning to create a high-resolution 3D topographical map of the existing teeth and alveolar ridges.2

Designing the framework with specific attention to the "overlaid" zones, ensuring uniform stress distribution across the supporting natural teeth.

A comparative analysis between Computer-Aided Manufacturing (CAM) milling of cobalt-chrome or high-performance polymers (PEEK) and Additive Manufacturing (3D Printing) for the framework.

The application of aesthetic composite or ceramic layers to replicate natural dental morphology.

Results: The implemented digital manufacturing method demonstrated a significantly higher degree of marginal fit (within $50-100 \mu m$) compared to traditional lost-wax casting techniques. The use of high-performance polymers in the framework reduced the "heavy" sensation for the patient while maintaining sufficient flexural strength to withstand masticatory forces.

Conclusion: Transitioning from analog to digital manufacturing methods for overlaid prostheses significantly minimizes human error and material shrinkage. This approach provides a predictable, repeatable, and bio-compatible solution for complex pediatric or adult dental reconstructions.