Digitally enhanced rehabilitation of an aramany Class I maxillary defect using a 3D-printed hollow bulb obturator: A clinical case report

Maxillary defects resulting from surgical resection for malignancies such as squamous cell carcinoma, present significant challenges in prosthodontic rehabilitation. Obturator prostheses remain the primary method for restoring oral function, speech, and esthetics in such patients. However, conventional fabrication techniques for hollow bulb obturators are labor-intensive, may lack anatomical precision and are heavily uncomfortable for the patient. This clinical case report describes the rehabilitation of a 76-year-old male with a history of squamous cell carcinoma and an Aramany Class I maxillary defect. A novel hybrid approach where a digital extraoral scan of the master cast was used to design the hollow bulb using Exocad software, and the bulb was fabricated via 3D printing with biocompatible surgical resin. The conventional denture base and teeth were processed using standard heat-cure techniques. The 3D-printed hollow bulb was later attached using clear acrylic. This digitally guided workflow provided enhanced precision, reduced prosthesis weight, and improved patient comfort. The integration of digital design with conventional processing exemplifies a promising advancement in maxillofacial prosthodontics, especially for complex defects. This case highlights the clinical utility and patient-centered outcome of incorporating CAD/CAM technology in obturator fabrication.