Use of an open-source CAD software program and additive manufacturing technology to design and fabricate a definitive cast for retrofitting a crown to an existing removable partial denture.

This technical report describes a digital process for designing and fabricating a stackable definitive cast and die system to facilitate the fabrication of a new surveyed crown to retrofit to a removable partial denture (RPD). By using an open-source computer-aided design (CAD) software program, this technique provides an economical option for dental clinicians and laboratory technicians to use intraoral scans and design a stackable definitive cast and die system with minimal financial investment in the CAD software. In addition, this technique provides the advantage of a conventional indirect technique in that it can create a definitive cast with an RPD clasp assembly ready for the dental technician to properly contour the new surveyed crown, but without the need for the patient to be without the RPD during the process.