Hybrid Digital-Conventional Protocol for Complete Removable Dentures in Totally Edentulous Patients: Workflow, Clinical Efficiency, Costs, and GOHAI Outcomes

Background 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 patients' perceived 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 utilizing structured anamnestic questionnaires and the General Oral Health Assessment Index (GOHAI), administered both prior to and following prosthetic rehabilitation. Results The hybrid digital protocol successfully facilitated the rehabilitation of all enrolled patients, with required clinical visits to 3–4 sessions and laboratory production time to 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 patients' perceived 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 feasibility, economic efficiency, and improved patient-reported outcomes concerning oral health and quality of life. The integration of digital scanning, modeling, and conventional fabrication methods reduced the number of clinical visits and optimized chairside and laboratory time. These findings support the clinical feasibility of this hybrid approach and suggest favorable effects on treatment efficiency and patient-reported outcomes in totally edentulous patients.