Comparing the Accuracy of Digital Impression Versus Conventional Impression for Okay’s Class 1b and Class 2 Maxillary Defects: A Pilot Clinical Study

Purpose Accurate impressions are essential for the successful fabrication of obturator prostheses in patients with maxillary defects. The emergence of digital intraoral scanning has introduced a potential alternative to conventional impression techniques. This study aimed to compare the accuracy, patient comfort, and clinical efficiency of digital impressions and conventional impressions in patients with Okay’s Class 1b and Class 2 maxillary defects. Materials and Methods A prospective pilot clinical study was conducted on 12 patients presenting with surgically acquired maxillary defects classified as Okay Class 1b or Class 2. Each patient underwent both digital and conventional impression procedures. Digital impressions were recorded using an intraoral scanner, whereas conventional impressions were made using custom trays and polyvinyl siloxane materials. Conventional casts were digitized using a laboratory scanner. Threedimensional deviation analysis was performed using surface matching software. Impression time and patient comfort were also evaluated. Results The mean deviation for digital impressions was 0.28 ± 0.09 mm, whereas conventional impressions showed a mean deviation of 0.34 ± 0.11 mm. The difference was not statistically significant (p = 0.08). Digital impressions required significantly less chairside time (7.2 ± 1.5 minutes) compared with conventional impressions (14.8 ± 2.3 minutes) (p < 0.01). Patient comfort scores were significantly higher for digital impressions (VAS score 8.6 ± 0.9) compared with conventional techniques (6.2 ± 1.4) (p < 0.01). Conclusion Digital impressions demonstrated comparable accuracy to conventional impressions for recording Okay Class 1b and Class 2 maxillary defects. Digital techniques significantly improved patient comfort and reduced impression time. Digital workflows may therefore represent a promising approach for maxillofacial prosthodontic rehabilitation.