Restoring a Face: How a 3D Printed Jaw Model Made an Impossible Obturator Possible

The patient was 41 years old when he was diagnosed with cancer of the palate — the upper jaw. He underwent a procedure called infra-structure maxillectomy, which involved the removal of the upper jaw and palate. The surgery exposed his nasal cavity and maxillary sinus to his oral cavity. He then received six weeks of radiotherapy.

The radiation left him with trismus — a severe reduction in mouth opening caused by fibrosis — limiting him to around 20 mm. Food entered through the defect into his nose. Speech was nasal and altered. His appearance was affected. Multiple dentists had attempted and refused to fit him with an obturator — the prosthetic device that would close the gap — because taking an impression of the jaw was impossible with such restricted mouth opening. His productive life had come to a halt.

A maxillofacial surgeon exploring new ways to solve the case got in touch with Osteo3d. A CT scan with 3D reconstruction was performed on the patient's face. From that data, Osteo3d 3D printed an anatomically accurate model of the mandible and maxilla — including the defect and the existing teeth. The model precisely replicated all the movements of the jaw joint.

This model made what had been impossible straightforward. A wax model of the obturator was fabricated using the 3D print as the base. A trial fitting was done on the patient — adjustments were made in the wax directly. Once the fit was confirmed, the wax was converted to acrylic and delivered to the patient.

The obturator restored his ability to eat, swallow, and speak normally. The nasal speech resolved. His smile returned. The surgical and prosthodontic team who completed this case captured the outcome in three words: "All Smiles."

This case, from late 2014, was among Osteo3d's earliest documented patient stories. It illustrated a principle that has stayed central to everything we do: when standard methods reach their limits, a patient-specific model derived from the actual anatomy can open up a path that did not previously exist.