Estudo comparativo entre os fluxos de trabalho analógico e digital na confecção de próteses nasais

Abstract

Facial mutilations resulting from oncological surgery sequelae, trauma, or necrosis have historically imposed complex challenges to aesthetic and functional rehabilitation. The loss of organs, particularly in the facial region—such as the eyes, nose, orbital cavity, lips, and maxilla/mandible—generates a profound psychosocial impact. This necessitates solutions that transcend surgical reconstructive capacity, making adhesive maxillofacial prostheses a fundamental resource for restoring aesthetics, function, and self-esteem. However, the fabrication of these devices via the analog (traditional) method is a time-consuming and essentially artisanal process, highly dependent on artistic proficiency, which limits the predictability and reproducibility of results. The adoption of digital methods emerges as a promising alternative for facial rehabilitation processes. With the primary objective of comparing the analog nasal prosthesis fabrication technique with the digital technique, this work conducted a comparative study encompassing five clinical cases. The study was based on the principles of the Project Development Guidelines (GODP). The methodological approach comprised an analytical and comparative description of both techniques, with an emphasis on the validation of materials and additive manufacturing protocols for mold production. Quantitative metrics, such as production time and the number of appointments, were evaluated alongside qualitative metrics, such as patient satisfaction. The results evidenced the operational superiority of the digital workflow over the analog technique, which proved to be dependent on exclusive “Active Operator” dedication at all stages. The research demonstrated that the use of vat photopolymerization 3D printing, combined with the developed surface treatment protocol, not only significantly reduced manual labor time and the number of clinical sessions but also ensured greater texture fidelity and predictability. Therefore, it is concluded that the optimization provided by the digital workflow establishes a more agile and reproducible process, allowing the prosthodontist to redirect clinical availability toward the most critical, aesthetic, and subjective phases of maxillofacial rehabilitation.