Overlaid Prosthesis Manufacturing Method Using Teeth

Abstract

Restorative treatments that strike a compromise between structural integrity and cosmetic needs are necessary for the rehabilitation of individuals with badly worn or partly edentulous dentition.1 Although overlay prostheses, also known as overlay dentures, provide a less invasive option than high-risk implants or regular extractions, their success is largely dependent on the manufacturing process' accuracy.

Goal: In order to improve the final restoration's fit, durability, and functional occlusion, this research outlines an improved manufacturing process for overlay prosthetic structures that integrates digital workflows and material science.

Methods: A multi-stage technique is used in the production protocol:

generating a high-resolution three-dimensional topographical map of the current teeth and alveolar ridges using intraoral scanning.2. Paying close attention to the "overlaid" areas while designing the framework to guarantee equal stress distribution among the natural teeth that support it.

For the framework, a comparison between additive manufacturing (3D printing) and computer-aided manufacturing (CAM) milling of cobalt-chrome or high-performance polymers (PEEK).

applying layers of ceramic or cosmetic composite to mimic the morphology of real teeth.

Results: When compared to conventional lost-wax casting methods, the digital production approach that was used showed a much greater degree of marginal fit (within 50-100 m). The framework's use of high-performance polymers lessened the patient's "heavy" feeling while preserving enough flexural strength to endure masticatory stresses.

Conclusion: Human error and material shrinkage are greatly reduced when overlay prostheses are manufactured using digital techniques instead of analog ones. For complicated dental reconstructions in children or adults, this method offers a reliable, reproducible, and biocompatible alternative.