Novel 3D Modeling Technique of Removable Partial Denture Framework Manufactured by 3D Printing Technology

The objective of the present study was to digitize the removable partial denture framework construction using a combination of simplified novel modeling technique and a 3D printing prototyping technology. A partially edentulous stone cast was selected representing mandibular Kennedy class I. The cast was optically scanned using desktop structured light scanner and the generated 3D model data was be exported as STL file then imported to universal reverse engineering software. The cast was digitally surveyed according to the selected path of insertion then all undesirable undercuts were selected, removed and blocked by flat surfaces. A stress releasing design for mandibular class I Kennedy was considered then the components were drawn and cut, as a thin shell, from a 3D model duplicate. Each component was offset outside the 3D model surface to a distance equivalent to its required relief. The framework volume was then created by thickening the shell surface followed by smoothening. Finally, the framework was fine-tuned using sculpt tool. The final framework 3D model was generated layer by layer using the 3D printer machine. The final framework was checked on the stone cast for error and fitness. The final outcome of the current technique produced precise and well-fitted removable partial denture framework using simplified, rapid yet accurate technique of modeling.