Patients: A 56-year-old man with a left-sided cleft lip and palate was referred to our department due to mastication and speech difficulties. His existing prostheses have become unstable owing to changes in the remaining dentition over 10 years. For the fabrication of the new interim maxillofacial prostheses, a digital impression technique was selected as the conventional technique posed medical risks due to hypermobile teeth and maxillary defects. New interim maxillofacial prostheses were fabricated using a combination of the digital impression technique and a bite-seating impression, performed with trial prostheses and impression material. The patient has been using the new interim prostheses comfortably since delivery. The oral functional evaluation yielded favorable results.

Discussion: Patients with cleft lip and palate should use their existing maxillofacial prostheses during the fabrication of new ones, even if they are of suboptimal quality. Although addressing these issues using conventional techniques is challenging, digital technology provides a viable solution. However, impression material is essential for capturing mucosal defects and complex anatomy in cleft lip and palate cases; therefore, digital data should be supplemented by either well-adjusted existing prostheses or bite-seating impressions using impression material before new prostheses fabrication. Although his occlusal force was lower than the criterion for the oral hypofunction test, his masticatory performance remained favorable. Speech analysis revealed persistent air leakage; however, all scores improved with the prostheses.

Conclusions: Digital technology has enabled the safe fabrication of interim maxillofacial prostheses, resulting in improved masticatory and speech performance.