Fabrication of a Maxillary Prosthesis for a Flap-Reconstructed Maxillary Defect Using a 3D-Printed Occlusal Record Base

The fabrication of maxillary prostheses in patients with flap-reconstructed maxillary defects continues to present both clinical and technical challenges. Conventional impression techniques can be hazardous and often require multiple adjustments. This report presents a simplified digital approach using 3D scan data of an existing, well-adjusted prosthesis. The previously relined and adjusted prosthesis was scanned with an intraoral scanner, and the 3D surface data were used to print an occlusal record base. After recording the jaw relation, the teeth were arranged, and a functional impression was made at the try-in stage. Finally, the definitive prosthesis was fabricated using heat-cured acrylic resin. The printed record base provided accurate adaptation and minimized the clinical risks associated with conventional impression making. Incorporating the functional impression during the try-in stage further improved the fit and reduced the need for postdelivery adjustments. This technique offers a practical and simplified method for maxillary prosthesis fabrication. Reusing the morphology of a clinically adapted prosthesis eliminates complex digital processing and reduces clinical burden, making it especially useful in settings with limited access to advanced technical support.