Digital workflow for fabricating a patient-specific detachable 3D-printing model for mesiodens extraction to enhance surgical planning and dental education

BACKGROUND: The purpose of this study was to introduce a unified single-platform workflow for fabricating a patient-specific, multi-material 3D printing model of an impacted mesiodens. The workflow integrates CBCT and intraoral scans within a single planning platform and incorporates a fully detachable modular design and an elastic gingival layer to enable realistic soft-tissue simulation and stepwise surgical rehearsal. CASE PRESENTATION: Cone-beam computed tomography (CBCT) and intraoral scans were obtained for a patient with a fully impacted mesiodens. Using a single planning platform, anatomic structures (including teeth, bone, and gingiva) were segmented, and modular, engaging components were designed using computer-aided design functions. A multi-material model with detachable layers was fabricated using 3D printing to permit stepwise rehearsal: flap design, osteotomy, and tooth removal. The model accurately reflected patient-specific anatomy, and the elastic gingival component enabled realistic soft-tissue manipulation. This enhanced the fidelity of preoperative planning and provided improved educational value by visualizing anatomical relationships in stages. CONCLUSIONS: This study demonstrates the feasibility of a unified single-platform workflow integrating CBCT and intraoral scans to produce patient-specific, detachable, multi-material 3D models. By combining modular design with soft-tissue simulation, the method supports clear, stepwise visualization of the mesiodens site.