Digital Removable Complete Dentures: A Hybrid Workflow for Improved Efficiency

Objectives: The present study aims to describe and evaluate a hybrid digital-conventional protocol for removable complete dentures, evaluating its clinical efficiency, economic advantages, and impact on self-perception of oral health and quality of life. Methods: Thirty fully edentulous patients aged over 65 years were recruited based on predefined oral health status and socio-economic criteria. A hybrid protocol integrating digital scanning, digital modeling and selective conventional fabrication steps was employed to produce removable complete dentures. Evaluated parameters included total clinical visits required, time spent during clinical sessions and laboratory production, prosthesis-related complications post-delivery, and overall production costs. Patient satisfaction and oral health-related quality of life were quantitatively assessed using structured anamnestic questionnaires and the General Oral Health Assessment Index (GOHAI), administered both before and after prosthetic rehabilitation. Results: The hybrid digital protocol successfully facilitated the rehabilitation of all enrolled patients, with required clinical visits ranging from 3 to 4 sessions and laboratory production time of approximately 6.5 hours per prosthesis, and an average fabrication cost of €300. Clinically, two instances of prosthesis fracture were recorded and managed without subsequent recurrence. No major complications were reported during a 6-month observational period. GOHAI assessment revealed statistically significant improvements in self-perception of oral health, comfort, and overall satisfaction after prosthetic treatment, although residual minor discomfort and aesthetic concerns persisted in some cases. Conclusions: The hybrid digital protocol for fabricating complete removable dentures demonstrated clinical efficacy, economic efficiency, and enhanced patient-reported outcomes concerning oral health and quality of life. The integration of digital scanning, modeling, and conventional fabrication methods resulted in a reduction in the number of clinical visits, time-efficient chairside and laboratory production, and overall improved patient comfort and satisfaction.