Complete Dentures Manufactured Using CAD/CAM Technology and a Modified Individual Tray Recording Method

Abstract

This study introduces the Tako tray, a modified individual tray designed for the closed-mouth impression technique, and demonstrates its integration with Ivotion CAD/CAM technology to enhance complete denture fabrication by combining conventional and digital workflows. A clinical case was conducted using the Tako tray to facilitate accurate impression-taking and jaw relation recording. Primary impressions were taken, followed by the fabrication of the Tako tray. The closed-mouth definitive impression was recorded in centric relation, simultaneously capturing functional and jaw relation records. The collected data were digitized and processed using the Ivotion CAD/CAM system for virtual denture design and milling. This approach streamlined the fabrication process and minimized patient visits. The integration of the Tako tray with the Ivotion workflow reduced clinical appointments to three, while improving occlusal rim retention and ensuring accurate jaw relation recording. The final dentures demonstrated precise fit, functional efficiency, and satisfactory esthetics, with the patient reporting high satisfaction. The combination of the Tako tray and digital technology optimized denture fabrication by increasing efficiency, reducing patient chair time, and achieving predictable, high-quality outcomes. Clinically, the Tako tray simplifies the closed-mouth impression technique, making digital workflows more accessible for complete denture cases while enhancing patient comfort and improving prosthetic results.

Keywords: complete denture; digital denture; modified individual tray.

Figure 1

Clinical workflows for digital complete denture fabrication.

Figure 2

Digital file of the edentulous jaws. (a) Upper jaw. (b) Lower jaw.

Figure 3

Digital design of the Tako tray with cylindrical poles. (a) Maxillary occlusal view. (b) Mandibular occlusal view. (c) Maxillary lateral view. (d) Mandibular lateral view.

Figure 4

Clear resin Tako tray with poles. (a) Maxillary occlusal view. (b) Mandibular occlusal view. (c) Maxillary frontal view.

Figure 5

Baseplate-occlusal rims with border molding using green stick compound. (a) Upper arch. (b) Lower arch.

Figure 6

Virtual teeth set up. (a) Teeth with individual corrections in size, shape, and position. (b) The scallop line showed the teeth-base junction.

Figure 7

Printed try-in dentures.

Figure 8

The digitally manufactured CD after the finishing and polishing procedures.

Figure 9

Insertion and delivery of complete denture. (a) Frontal view. (b) Maxillary occlusal view. (c) Mandibular occlusal view.