Computer-aided design and 3D fabrication of a segmented silicone obturator–RPD prosthesis for rehabilitating maxillary defects

Maxillary defects often result from tumor resection, congenital malformation, trauma, or infection, leading to functional and esthetic impairments such as difficulties in swallowing, speech, and mastication and altered facial appearance. 1 Rehabilitation with an obturator combined with a removable partial denture (RPD) remains the mainstay for restoring patients with palatal defects.Traditionally, the 1-piece obturator-RPD, fabricated with polymethyl methacrylate (PMMA) has been widely applied in clinical practice. 2However, their excessive bulk and weight, monolithic design, and fabrication-related errors compromise retention, comfort, hygiene, maintenance, reproducibility, and precision. 3,4ith the rapid advancement of digital technologies -including computer-aided design and computer-aided manufacturing (CAD-CAM), 3-dimensional (3D) printing, and digital scanning-together with the introduction of new materials, such as elastic silicone and printable resins, segmental, split, or 2-piece obturator-RPDs based on a fully digital workflow have emerged as a focus in research and clinical applications. 5he core principle of the digital segmental obturator-RPD approach is to design and fabricate the