A Personalized 4D Workflow for the Manufacturing of Functional and Removable Esthetic Devices: A Technical Report

Objective: This technical report describes a fully digital workflow for the manufacturing of a functional removable esthetic device (FRED) that addresses multiple clinical scenarios before prosthetic rehabilitation. The proposed method integrates advanced digital tools to achieve functional and esthetic outcomes while ensuring reversibility and patient comfort. Clinical Considerations: The workflow includes intraoral and facial scanning, jaw motion tracking, and CAD/CAM technology to create a 4D virtual patient. This allows for a precise recording of the maxillomandibular relationship and facilitates the determination of the comfort position to establish a new occlusal vertical dimension (OVD). FRED is a custom-designed, removable, tooth-colored device manufactured to provide temporary functional support, esthetic preview, catering to different clinical scenarios, including tooth wear, occlusal trauma, and periodontal conditions. Conclusions: This technique combines digital and traditional prosthetic principles into a patient-centered, adaptable workflow, allowing precise, non-invasive, and dynamic evaluation of OVD modifications. By integrating digital recording, facial scanning, and CAD/CAM fabrication, it enhances function, esthetics, and patient comfort. Clinical Significance: This technique highlights the synergy of digital innovation and prosthetic principles, enhancing diagnostic capabilities and treatment predictability. The patient-centered design supports functional stability and esthetic outcomes, making it a valuable tool in modern prosthetic dentistry.