Written by: Jacob Kaufman, DMD
Introduction
Digital workflows have improved the efficiency and experience of complete denture fabrication—streamlining production, reducing chair time, and minimizing patient visits. However, until recently, the digital denture protocol lacked a reliable soft reline material that could bond effectively to 3D-printed resins. Rodin Soft Reline (Pac-Dent) overcomes this limitation with a chairside-compatible material that securely bonds to printed denture bases, providing a cushioned fit for immediate or complete dentures that require a reline.
This case study highlights a fully digital approach to immediate dentures using Rodin Soft Reline in a 63-year-old male with terminal dentition and impaired oral function. The patient’s priority was to restore masticatory function and aesthetics in a single visit. Using a fully digital design-fabrication workflow and Rodin Soft Reline, we delivered an aesthetic and retentive provisional prosthesis at the time of extractions.
Case Background
The patient presented with caries, stage IV Grade C periodontitis, and partial edentulism (Figures 1 to 3). After discussing all treatment options, the patient elected to have immediate complete dentures as the definitive treatment plan, with future re-evaluation for implant placement.
Workflow and Product Integration
A digital workflow was used to fabricate the provisional denture. Preliminary records were captured using intraoral scans, facial photography, and a leaf gauge for bite registration and vertical dimension assessment. These digital records were used to fabricate a monolithic interim denture printed in Rodin Sculpture B1 on a Sonic Mini 8K Resin 3D Printer (Phrozen). Characterization was completed using the Rodin Palette (Pac-Dent), glazed with Rodin Glaze (Pac-Dent), and then final cured in nitrogen with the Otoflash unit (Figures 4 to 6).
The extractions and alveoloplasty were completed without complication. The denture fit was verified, and gingival suturing was completed with chromic gut using the Texas Two-Step suture technique (Figures 7 and 8).
Rodin Soft Reline was applied chairside following tissue suturing. Both maxillary and mandibular intaglio surfaces were primed according to the manufacturer’s instructions, and reline material was dispensed into the provisional restoration (Figures 9 to 11). The dentures were seated simultaneously, and border molding movements were performed manually by the provider. To avoid sutures becoming embedded in the reline material, the dentures were gently removed at 90 seconds and reseated prior to full polymerization. This variation from the listed IFU technique avoids suture tugging with no notable compromise in adaptation. Excess material was removed from the denture flange with a 15-blade. Projections of soft liner that extended into the extraction sockets were trimmed with rongeurs to allow for a uniform arch form after healing (Figure 12).
Outcomes
The immediate reline resulted in a stable, retentive provisional denture. The patient reported minimal pain, which was managed with ibuprofen and acetaminophen. He returned the following day with no sore spots or chief complaints. Sutures were removed after 1 week. A second reline was performed at 6 weeks postoperatively to accommodate bone remodeling and tissue shrinkage. Rodin Soft Reline remained fully bonded to the printed bases after both relines, with no signs of delamination or detachment (Figures 13 and 14).
Final prostheses were fabricated 6 months postop. The provisional denture was used as a custom tray, and the impression was made using light-body PVS for a wash impression (Take 1 Advanced Light Body Wash [Kerr]). The prostheses were made using Rodin Denture Base 2 (Pac-Dent) in Meharry and Rodin Sculpture in B1. Aesthetic enhancements were completed using Rodin Palette and Rodin Glaze. The patient expressed satisfaction with the aesthetics and function of the final denture (Figures 15 and 16). The denture presented with adequate retention and stability.
Discussion
Rodin Soft Reline fills a critical gap in digital denture workflows. Its ability to bond to printed resins enables same-day soft reline delivery, which was not previously achievable. Clinically, it provides excellent adaptation, comfort, and retention without being overly technique sensitive. Its low viscosity allows for even flow and palatal coverage.
In comparison to traditional relines that fail to adhere to 3D materials, Rodin Soft Reline offers superior ease of use and longevity. Both the immediate and 6-week relines remained securely attached throughout the healing process. The brief removal at the semi-set stage eliminated suture tugging. Anecdotally, Rodin Soft Reline appears to reduce the incidence of sore spots and postop discomfort.
For clinicians incorporating 3D-printed dentures, this material is highly practical and reliable. It simplifies delivery, improves patient comfort, and supports long-term tissue health.
ABOUT THE AUTHOR
Dr. Kaufman graduated from Oregon Health & Science University School of Dentistry. He owns Roots Dental Gresham in Gresham, Ore, and is a partner in the Arvory Dental Group. His clinical focus is in digital dentistry and implant therapy. With a background in software development, Dr. Kaufman mentors dentists in 3D printing and collaborates with an international team on CAD design. His efforts center on advancing digital workflows to improve treatment outcomes and predictability. He can be reached via email at [email protected].
Disclosure: Dr. Kaufman reports no disclosures.
