Odovtos-International Journal of Dental Sciences (Odovtos-Int. J. Dent. Sc.), Online First, 2026. ISSN: 2215-3411

https://doi.org/10.15517/tn5cn648

https://revistas.ucr.ac.cr/index.php/rOdontos

CASE REPORT:

Primary Anterior Teeth Rehabilitation with 3D-Printed Resin Crowns in a Digital Workflow: Case Report

Rehabilitación de anteriores primarios con coronas impresas dentro del flujo digital: Reporte de caso

Alejandra Porras Zúñiga DDS, MSc1 https://orcid.org/0009-0001-0270-0495

Francisco Porras Arancibia DDS2 https://orcid.org/0009-0001-2235-4462

María F. Rodríguez Callaci DDS3 https://orcid.org/0009-0002-4290-8503

1Pediatric Dentist, Director and Professor in the Department of Pediatric and Orthodontics, Faculty of Dentistry, University of Costa Rica, San José, Costa Rica.

2Professor in the Department of Pediatric and Orthodontics, Faculty of Dentistry, University of Costa Rica, San José, Costa Rica.

3Private Practice, San José, Costa Rica.

Correspondence to: Alejandra Porras Zúñiga DDS, MSc - ALEJANDRA.PORRAS@ucr.ac.cr

Received: 11-XI-2025 Accepted: 19-III-2026

ABSTRACT: Severe early childhood caries is among the most prevalent oral conditions in children and may significantly affect health, esthetics, and self-esteem. Finding restorative solutions that are both functional, esthetic, and well accepted by young patients can be a clinical challenge, especially in primary anterior teeth with extensive structural loss. This report presents the case of a 5-year-2-month-old boy with multiple carious lesions in the primary dentition, a high caries risk profile, and a strong esthetic concern shared by both the child and his mother. After completing the urgent and stabilization phases, the maxillary primary incisors were rehabilitated using 3D-printed crowns, prioritizing patient comfort and procedural simplicity. The digital workflow included intraoral scanning, customized anatomical design with Exocad® DentalDB 3.2, and additive manufacturing using biocompatible Crowntec® resin. The crowns were placed without complications and with excellent patient cooperation. Follow-up visits at one, three, and six months demonstrated proper adaptation, stability, and excellent gingival response. Both the child and his mother expressed satisfaction with the esthetic and functional outcome. The use of 3D-printed crowns in pediatric patients with early childhood caries represents a viable and effective restorative option that combines technical precision with esthetic, emotional, and psychosocial benefits, contributing not only to oral health but also to the child’s overall well-being.

KEYWORDS: Early childhood caries; 3D-printed crown; Esthetic rehabilitation; Digital workflow; Pediatric dentistry; Case report.

RESUMEN: La caries de la temprana infancia severa es una de las afecciones más comunes en la infancia y puede comprometer seriamente la salud, la estética y la autoestima del niño. En casos donde los dientes temporales anteriores presentan una destrucción extensa, encontrar soluciones restauradoras que sean funcionales, estéticas y bien aceptadas por el paciente representa un reto clínico. Este reporte describe el tratamiento de un niño de 5 años y 2 meses con múltiples lesiones cariosas en dentición temporal, alto riesgo cariogénico y un fuerte deseo, expresado tanto por él como por su madre, de recuperar una sonrisa estética. Tras una fase de urgencia y estabilización, se decidió rehabilitar los incisivos superiores temporales con coronas impresas en 3D, priorizando la comodidad del paciente y la simplicidad del procedimiento. El proceso se llevó a cabo mediante escaneo intraoral, diseño anatómico digital personalizado con software Exocad DentalDB 3.2 y fabricación aditiva en resina biocompatible Crowntec®. Las coronas se colocaron sin complicaciones, con excelente colaboración del paciente. En los controles a 1, 3 y 6 meses, las restauraciones mostraron adaptación adecuada, estabilidad y buena respuesta gingival. Tanto el niño como su madre expresaron satisfacción con los resultados, destacando la mejora estética y el impacto positivo en su actitud. El uso de coronas impresas en 3D en pacientes pediátricos con caries de la temprana infancia, ofrece una alternativa viable y efectiva, que combina precisión técnica con beneficios estéticos y emocionales, contribuyendo no solo a la salud oral, sino también al bienestar integral del niño.

PALABRAS CLAVE: Caries de la temprana infancia; Coronas impresas en 3D; Rehabilitación estética; Flujo digital; Odontología pediátrica; Reporte de caso.

INTRODUCTION

Early childhood caries (ECC) is one of the most common chronic pediatric conditions and represents a major public health challenge, particularly in developing countries (1). ECC is defined as the presence of one or more decayed (noncavitated or cavitated), missing (due to caries), or filled, primary tooth surfaces in children under 6 years of age (2). Its onset is strongly associated with frequent consumption of a sugar-rich foods and liquids, poor oral hygiene, and lack of regular dental checkups. Beyond these clinical consequences, ECC may also affect a child’s emotional and social well-being, particularly when the esthetic compromise is evident (3-5). This was the case for the patient in this report: as noted by his mother, the child’s preschool teacher observed that the deterioration of his anterior teeth was noticeable when he smiled, leading him to avoid smiling because of their appearance. This emotional and social impact underscored the importance of an esthetic rehabilitation.

In advanced cases, the structural destruction caused by ECC can significantly complicate restorative management, particularly in very young patients with limited cooperation in the dental chair. Therefore, it becomes essential to select restorative solutions that not only ensure functionality and durability but also satisfy esthetic demands and can be completed within a limited number of clinical sessions (6,7).

Recently, 3D-printed crowns have gained increasing attention as an innovative restorative option, particularly in pediatric dentistry. These digitally designed and additively manufactured restorations offer a high level of anatomical customization, excellent marginal adaptation, and esthetic outcomes closely resembling natural teeth (8-10). Moreover, their use has been associated with reduced clinical chair time-a key advantage in managing pediatric patients with limited attention spans or cooperation (11). Recent studies support their clinical effectiveness, reporting mechanical properties comparable to conventional materials such as polymethyl methacrylate and zirconia, while demonstrating more favorable gingival responses (12-14).

This case report describes the clinical management of a pediatric patient with severe ECC, involving the rehabilitation of the maxillary primary incisors with 3D-printed crowns. The treatment was part of a comprehensive care plan that prioritized not only oral health but also esthetic, functional, and emotional well-being.

This case expands the existing evidence by documenting, for the first time, the rehabilitation of maxillary primary incisors using 3D-printed crowns within a complete digital workflow, providing six-month clinical follow-up in a university setting and extending current knowledge beyond in vitro studies and the few reports limited to other conditions such as amelogenesis imperfecta.

CASE REPORT

Patient Information

A 5 years and 2 months old male patient was brought by his mother to the Pediatric Dentistry and Interceptive Orthodontics Clinic, School of Dentistry, University of Costa Rica. The mother expressed concern about the advanced deterioration of her son’s teeth. The child had no relevant medical, systemic, or allergic history, was in good general health, and demonstrated a cooperative attitude during the consultation.

The patient presented with poor oral hygiene, showing a Modified Greene and Vermillion Dental Biofilm Index score of 1.34. Dietary analysis showed a Cariogenic Diet Index score of 83, indicating frequent nocturnal intake of sugar-containing liquids, including chocolate milk, infant formula, and nutritional supplements. These findings placed the patient in the high caries-risk category.

Clinical Examination and Diagnosis

The clinical examination revealed multiple severe carious lesions affecting the primary posterior teeth. Tooth 5.5 was diagnosed with irreversible pulpitis and tooth 8.5 with pulpal necrosis; both were considered non-restorable.

In the maxillary anterior region, the lateral incisors (teeth 5.2 and 6.2) showed severe structural loss without pulp exposure. The central incisors (teeth 5.1 and 6.1) exhibited advanced palatal-distal carious lesions, with vestibular cavitation observed in tooth 5.1. Despite the extensive structural deterioration, no clinical signs of irreversible pulpitis or pulpal necrosis were detected.

Radiographic evaluation confirmed the integrity of the roots of the maxillary primary incisors and normal development of the permanent successors, with no evidence of periapical pathology. According to the diagnostic criteria of the American Academy of Pediatric Dentistry (AAPD), this case was classified as severe early childhood caries (S-ECC) in an advanced stage. From an orthodontic perspective, the patient exhibited a convex facial profile, increased overjet and overbite, and a bilateral Class II molar relationship.

Treatment Plan

The clinical approach was divided out into three phases:

Emergency phase: Pain relief was prioritized due to pulpal involvement of tooth 5.5, which required extraction. Other extensive cavitated lesions were also treated to prevent further caries progression.

Stabilization phase: Caries risk was reduced through education of both the mother and child, emphasizing oral hygiene instructions and dietary modifications.

Rehabilitation phase: Once the clinical and behavioral conditions were stabilized, esthetic and functional rehabilitation of the maxillary primary incisors was performed using 3D-printed crowns. This decision reflected the child’s esthetic motivation, as he explicitly expressed a desire to avoid “metal teeth”, referring to stainless steel crowns.

The digital workflow included intraoral scanning, individualized anatomical design with Exocad® DentalDB 3.2 software, and additive manufacturing using biocompatible Crowntec® resin (Saremco). The crowns were cemented with Duolink® resin cement under relative isolation, with excellent patient cooperation.

Table 1 presents a concise and structured overview of the clinical events that occurred throughout the course of the patient´s treatment and rehabilitation.

TREATMENT

The maxillary anterior rehabilitation phase focused on restoring the primary incisors (teeth 5.2, 5.1, 6.1, and 6.2), given their esthetic and functional importance and the child’s strong motivation to regain his smile. Because of interruptions in the treatment timeline, valuable rehabilitation time had been lost. Considering the extent of structural damage, the limited eruption period remaining for the permanent successors (teeth 1.1 and 2.1), and the patient’s desire to avoid metallic restorations, 3D-printed crowns were selected as an esthetic alternative to prefabricated stainless steel crowns.

Clinical Workflow

The clinical workflow comprised several steps. Intraoral scanning was performed using a 3Shape® Trios 3 Wired scanner, capturing the morphology of the affected teeth without the need for conventional impressions and thereby improving the patient’s comfort and experience. A customized digital design was generated utilizing Exocad® software, incorporating a predesigned tooth library to accurately reproduce the natural anatomy of the maxillary primary incisors, adapted to the patient’s size and occlusion, with a crown thickness of approximately 0.5 mm in the cervical area and 1.0 mm in the incisal region, the latter being further adjusted intraorally to accommodate the patient’s occlusion.

The restorations were 3D printed using DLP technology (Anycubic Photon Mono D2® printer) with Crowntec® resin (Saremco, Switzerland), a biocompatible dental material with mechanical properties suitable for primary teeth. The total printing time was approximately 40 minutes. Post-processing involved cleaning in an Anycubic Wash and Cure unit with 95% isopropyl alcohol for 10 minutes, as recommended by the manufacturer, followed by a 20-minute UV post-curing cycle to ensure complete polymerization.

A clinical try-in was performed prior to cementation to verify proximal contacts and marginal adaptation. Cementation was carried out under relative isolation with cotton rolls and gauze in combination with low and high volume suction. The clinical protocol included prophylaxis with water, selective enamel etching using 37% phosphoric acid for 15 seconds, followed by thorough rinsing and controlled drying. A universal adhesive ALL-BOND Universal®️ (Bisco, USA) was then actively applied and light cure, prior to cementation of the 3D printed crowns with Duolink® dual-cure resin cement (Bisco, USA).

The entire procedure was completed in a single clinical session without the need for local anesthesia, owing to the patient’s excellent cooperation. This operational efficiency represented a significant advantage in pediatric management, minimizing fatigue and anxiety during dental care. The child’s active participation, combined with the minimally invasive approach, fostered a positive dental experience and reinforced adherence to the treatment plan. The result was a functional, esthetic, and biologically harmonious rehabilitation.

RESULTS

Follow-up evaluations were conducted at 1, 3, and 6 months after cementation, documenting the following clinical observations:

Clinical and Radiographic Documentation

Visual documentation was essential to evaluate treatment progress and to demonstrate the stability of the clinical outcomes achieved.

Extensive carious lesions with structural loss and dentin exposure were observed in teeth 5.2, 5.1, 6.1, and 6.2. The aesthetic and functional impacts were evident during the initial consultation (Figure 1).

The images reveal advanced structural loss of the maxillary primary incisors (Figure 2. A-B).

CAD representations were created using Exocad® software, illustrating the individualized anatomic morphology of each primary crown based on the patient’s intraoral scan (Figure 3. A-B).

The cementation procedure was performed under carefully controlled relative isolation, following the complete protocol for Duo-Link®️ resin cement (Bisco, USA). Moisture control was achieved using cotton rolls and gauze in combination with both low- and high-volume suction.

Selective enamel etching was carried out using 37% phosphoric acid (3M, USA) applied exclusively to enamel surfaces for 15 seconds, followed by thorough rinsing and controlled air-drying. A universal adhesive (ALL-BOND Universal®️, Bisco, USA) was then actively applied and light-cured according to the manufacturer’s instructions prior to cementation of the 3D-printed crowns (Figure 4. A-B-C).

Excellent esthetic integration, symmetry, and an adequate emergence profile of the rehabilitated incisors were observed (Figure 5).

Excellent marginal adaptation was observed, and physiological root resorption of teeth 6.1 and 5.1 was evident at the three-month follow-up (Figure 6).

Radiographic follow-up confirmed proper marginal adaptation of the crowns (Figure 7).

Table 1. Clinical timeline of the case.

Clinical Phase

Relevant Clinical Events

Observations

Initial consultation

Medical history and clinical examination. Diagnosis of severe early childhood caries (S-ECC). Comprehensive treatment planning.

Cooperative patient. The mother was motivated by esthetic considerations.

Emergency phase

Extraction of tooth 5.5 (due to irreversible pulpitis).

—

Stabilization phase

Educational interventions (oral hygiene and dietary control). Initiation of restorative treatment in primary molars.

High caries risk.

Treatment interrupted

Treatment interrupted for 10 months. Diagnosis of pulp necrosis in tooth 8.5.

Regression in oral condition.

Maxillary anterior rehabilitation phase

Treatment resumed, posterior needs managed. Intraoral scanning and digital crown design. Cementation of 3D-printed crowns in maxillary primary incisors (5.2, 5.1, 6.1, and 6.2).

Esthetic and functional restorations; high satisfaction reported by patient and mother.

Clinical postoperative 1 and 3 months follow-up

Clinical postoperative evaluations were conducted at 1 and 3 months after crown cementation and were based on a subjective clinical assessment.

Clinical evaluation revealed healthy gingival

tissues, with pink coloration, firm consistency, absence of bleeding, and stable

gingival margins. Physiological root resorption of 5.1 and 6.1 observed in radiograph

Radiograph and clinical postoperative 6 month follow-up

5.1 and 6.1 mobility

Minor gingival erythema (5.1 and 6.1)

Advance physiological root resorption of 5.1 and 6.1 observed in radiograph

Figure 1. Initial clinical appearance of the maxillary primary incisors.

Figure 2. A-B. Diagnostic radiographs.

Figure 3. A-B. Digital anatomical design of 3D-printed crowns.

Figure 4. A-C. Cementation protocol.

Figure 5. Immediate postoperative intraoral photograph.

Figure 6. Three-month clinical follow-up.

Figure 7. Six-month periapical radiograph.

DISCUSSION

Comparison with Other Pediatric Crowns

The restorative management of primary teeth with extensive structural loss has traditionally relied on prefabricated metallic or celluloid crowns. Stainless steel crowns offer excellent mechanical durability but present esthetic limitations, variable marginal adaptation in cases of severe coronal destruction, and reduced retention when minimal tooth structure remains (15,16). In this case, the child’s mother expressed complete rejection of the use of stainless steel crowns.

Conversely, celluloid strip crowns filled with composite resin offer favorable esthetics and good retention; however, they require a dry operative field, depend on active patient cooperation, and are more technique-sensitive (17,18).

3D-printed crowns not only match the mechanical performance of zirconia crowns but also provide clinically reliable adaptation, offering esthetic and functional restorations that address pediatric patients’ emotional and behavioral needs (19). As an alternative to prefabricated zirconia crowns, 3D-printed crowns demonstrate comparable—and, in some cases, superior—fracture resistance to NuSmile® zirconia crowns. This is an encouraging finding, considering that 3D printing additionally enables anatomical customization and greater accessibility (8).

Treatment with 3D-printed crowns was chosen in this case to minimize chair time while ensuring predictable outcomes in terms of strength, color stability, and marginal fit. Several studies confirm that 3D-printed crowns provide superior marginal adaptation, reduced microleakage, and stable color performance, all of which contribute to excellent clinical outcomes (7,12,19).

Behavioral and Esthetic Advantages in Pediatric Patients

The emotional and motivational impact of esthetic rehabilitation represented a key aspect of this case. The patient expressed a strong desire to have teeth “like everyone else,” which became a decisive factor in shaping the treatment plan. Restoration of the anterior segment with personalized, natural-looking crowns elicited a highly positive response from both the child and his mother.

The decision to rehabilitate all four maxillary primary incisors was driven by the child’s need to perceive healthy anterior teeth, particularly after a prolonged and interrupted treatment course. At the time of treatment planning, delayed exfoliation of these teeth was evident, supporting their temporary preservation. The mother was informed that the central incisors (6.1 and 5.1) would remain in situ for only a short period, but their restoration would not involve additional or more invasive procedures than those performed on the lateral incisors.

Recent studies support this approach, showing that esthetic restorative treatments enhance pediatric patients’ self-esteem and promote better treatment compliance, follow-up, and attendance at subsequent checkups (20,21). This psychosocial dimension should be regarded as an integral component of clinical success in pediatric dentistry, particularly in preschool-aged children.

The Impact of Digital Workflow

The implementation of a complete digital workflow-from intraoral scanning to CAD design and additive CAM fabrication-enabled a precise, efficient, and minimally invasive rehabilitation. Digital scanning eliminated the discomfort associated with conventional impressions-such as gag reflex or aversion to impression materials-thereby significantly improving the patient’s overall experience (22).

Additionally, individualized anatomical design with Exocad® software allowed customization of each crown according to the patient’s morphology, respecting emergence profiles, incisal guidance, and occlusion. Printing with DLP technology using Crowntec® resin produced restorations with well-defined margins, appropriate surface texture, and harmonious morphology.

From an operative standpoint, the use of 3D-printed crowns reduced chair time and eliminated the need for lengthy procedures. This proved particularly advantageous given the patient’s previous cooperation challenges and the fatigue observed during earlier treatment phases. Increasingly supported in the literature, this digital approach has been recognized as a valuable tool for improving both technical accuracy and behavioral management in pediatric dentistry (9,14,23).

Clinical Considerations and Future Perspectives

Despite the favorable outcomes observed, this case presents certain limitations. First, follow-up visits were limited to six months; although a longer-term evaluation of crown performance would be desirable, it is inherently constrained by the physiological exfoliation of the primary teeth. Additionally, with the mother’s informed consent, rehabilitation was performed on all four maxillary incisors, even though two of them (5.1 and 6.1) were expected to remain in situ only for a short period, as physiological resorption was already evident at the three-month follow-up. Finally, the 3D printer used (Anycubic Photon Mono D2®) does not yet have full regulatory validation, which limits the generalizability of this protocol.

Nevertheless, this report provides a solid foundation for future research on the clinical longevity of 3D-printed crowns in the primary anterior segment, their resistance to occlusal load, and their long-term gingival response. Furthermore, it opens promising avenues for evaluating the impact of digital workflows on patient and caregiver perceptions, particularly within university or community settings where access to certified technology may be limited.

Key Clinical Takeaway

3D-printed crowns represent an effective restorative option for primary anterior teeth, combining esthetics, technical precision, and behavioral advantages. Their integration into comprehensive digital workflows offers a genuine opportunity to transform pediatric dental care into a more humane, efficient, and patient-centered practice.

The use of highly biocompatible resin materials, as demonstrated in this case, represents a favorable option for the rehabilitation of primary anterior teeth. Their adaptation and esthetic properties are well suited to the limited time these teeth remain in the oral cavity, making them a practical and predictable restorative solution for pediatric patients.

Finally, from an institutional perspective, the implementation of 3D-printed crowns requires an initial investment in digital infrastructure, including intraoral scanners, design software, and printing equipment. In university settings, these costs may be justified by their substantial educational value, as they enable students to progressively engage with, practice, and gain hands-on experience in digital workflows that are increasingly integral to contemporary dental practice. In the present case, the student responsible for the patient’s care performed the intraoral scanning procedures as an integral part of the clinical protocol under direct faculty supervision. The favorable clinical outcomes observed, together with advantages such as reduced chair time and an appropriate clinical response, support the relevance of this technology within a university clinic, where such experiences allow students to become familiar with digital workflows and to consolidate competencies that are essential for their professional development.

COMPLIANCE WITH ETHICAL STANDARDS

This clinical case was conducted in accordance with the ethical principles established for pediatric dental care, ensuring the protection of the child’s rights, safety, and well-being throughout all stages of treatment. Prior to any clinical procedure, written informed consent was obtained from the patient’s mother, who was fully informed about the diagnosis, available treatment options, potential benefits and risks, and the possibility of documenting and publishing the case for academic purposes.

Confidentiality and anonymity of the patient’s identity were guaranteed in compliance with institutional and journal policies on personal data protection. Consent explicitly included authorization for the use of clinical records, diagnostic images, intraoral and extraoral photographs, and treatment outcomes for inclusion in this scientific publication. The patient’s mother actively participated in the therapeutic decision-making process, particularly regarding the choice of restoration type, which was respected at all times in accordance with the principle of autonomy.

Funding: None.

Conflicts of Interest: The authors declare no potential conflicts of interest regarding this article's authorship and/or publication.

AUTHOR CONTRIBUTION STATEMENT: Conceptualization and design: A.P.Z. and F.P.A.; Literature review: A.P.Z., F.P.A., and M.F.R.C.; Clinical managment and supervision: A.P.Z., F.P.A., and M.F.R.C.; Digital workflow and technical procedure: F.P.A.; Resources: A.P.Z., F.P.A.; Original draft preparation and writing: A.P.Z.; Writing, review, and editing: A.P.Z., F.P.A., and M.F.R.C.; Supervision: A.P.Z.

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