Fabrication of milled removable partial dentures using a custom plate with prefabricated artificial teeth.

Purpose: Although digital removable partial dentures have been previously described, there have been no reports on how to fabricate them in one piece. This study proposes a new method for fabricating patient-specific digital removable partial dentures using a custom plate.

Methods: First, a gypsum model was scanned using a laboratory scanner and a removable partial denture was designed using computer-aided design (CAD) software based on standard tessellation language data. The metal clasp was fabricated from Ti-6Al-4V using a 3D printer. For custom plate fabrication, a resin plate frame was designed using computer-aided design (CAD) software and fabricated using a 3D printer. An artificial tooth and metal clasp were fixed on the base surface of the frame, an auto-polymerizing resin was poured into the frame for the denture base, and the artificial tooth and metal clasp were packed to form a custom plate. The plate was cut using a milling machine. Subsequently, the support attached to the denture was removed and polished for complete fabrication of the denture.

Conclusions: Our novel removable partial denture fabrication method is more efficient than the conventional method. The obtained removable partial dentures demonstrated satisfactory accuracy.