The treatment of maxillofacial defects presents significant challenges due to the complexity of facial anatomy and the diversity of affected tissues. Traditional workflows are labor-intensive, costly, and limited in customization. Recent advancements in fully digital workflows and direct 3D printing technologies offer new possibilities for improving the fit, aesthetics, and efficiency of prosthetic manufacturing. This scoping review aims to evaluate the current state of direct 3D printing for maxillofacial soft prostheses, assess material properties and biocompatibility, and identify challenges and future directions in this field. Methods: A comprehensive search of PubMed and Scopus databases, along with a manual search of relevant journals, was conducted to identify studies published up to December 2024. Articles focusing on direct 3D printing of maxillofacial soft prostheses were included, while studies involving traditional or mold-based workflows, ocular prostheses, and literature reviews were excluded. Data on materials, manufacturing techniques, and clinical outcomes were extracted and analyzed. Results: Out of 898 articles screened, 11 were included, 5 of which were in vivo studies (case reports). The additive manufacturing methods used in these case reports were Drop-on-Demand (DoD) silicone printing and PolyJet technology. Conclusions: Fully digital workflows and direct 3D printing technologies show promise for advancing maxillofacial prosthesis manufacturing. However, the absence of dedicated software, biocompatible materials, and medium- to long-term clinical evaluations highlight significant research gaps. Future research should focus on material development, workflow optimization, and clinical validation to enable widespread clinical adoption.

Background/Objectives: Auricular epitheses play a vital role in restoring facial symmetry and patient confidence following congenital or acquired defects. Traditional wax-based fabrication is labor-intensive and lacks reproducibility. This study proposes and evaluates a simplified, digitally driven workflow for auricular prosthesis manufacturing, integrating virtual patient creation, mirrored ear design, and three-part mold fabrication using two design platforms—CATIA V5R21 (industrial CAD) and Blender (open-source graphics software). Key outcomes include mold reusability, patient-centered evaluation, and workflow feasibility. Methods: A 28-year-old female patient with right-sided microtia was selected. A light-based 3D facial scan was performed, and the intact contralateral ear was mirrored and adapted virtually to the defect site. Molds were designed in both CATIA and Blender using a standardized three-parallelepiped approach and printed using FDM technology (Elegoo Neptune 4 Plus). Five silicone epitheses were carefully fabricated with each mold. Surface trueness was evaluated with Geomagic Control X, while subjective assessments were conducted by an independent prosthetic team and the patient using Visual Analogue Scales (VAS). Results: Both design workflows resulted in clinically usable prostheses. No statistically significant difference in RMS deviation was observed (p = 0.53), although CATIA-derived epitheses achieved higher subjective scores (mean 9.22/10) compared to Blender (mean 7.67/10). The preferred prosthesis (CATIA #4) was selected for final pigmentation and delivery to the patient. All molds were reused five times without any structural damage or significant signs of wear. Conclusions: This study demonstrates that both CATIA and Blender can support an effective, patient-centered digital workflow for auricular prosthesis fabrication. The methodology enables reproducibility, mold reusability, and improved clinical accessibility of custom prosthetics.

Background/Objectives: Auricular epitheses play a vital role in restoring facial symmetry and patient confidence following congenital or acquired defects. Traditional wax-based fabrication is labor-intensive and lacks reproducibility. This study proposes and evaluates a simplified, digitally driven workflow for auricular prosthesis manufacturing, integrating virtual patient creation, mirrored ear design, and three-part mold fabrication using two design platforms—CATIA V5R21 (industrial CAD) and Blender (open-source graphics software). Key outcomes include mold reusability, patient-centered evaluation, and workflow feasibility; Methods: A 28-year-old female patient with right-sided microtia was selected. A light-based 3D facial scan was performed, and the intact contralateral ear was mirrored and adapted virtually to the defect site. Molds were designed in both CATIA and Blender using a standardized three-parallelepiped approach and printed using FDM technology (Elegoo Neptune 4 Plus). Five silicone epitheses were fabricated with each mold. Surface trueness was evaluated with Geomagic Control X, while subjective assessments were conducted by an independent prosthetic team and the patient using Visual Analogue Scales (VAS); Results: Both design workflows resulted in clinically usable prostheses. No statistically significant difference in RMS deviation was observed (p = 0.53), although CATIA-derived epitheses achieved higher subjective scores (mean 9.22/10) compared to Blender (mean 7.67/10). The preferred prosthesis (CATIA #4) was selected for final pigmentation and delivery. All molds were reused five times without structural damage; Conclusions: This study demonstrates that both CATIA and Blender can support an effective, patient-centered digital workflow for auricular prosthesis fabrication. The methodology enables reproducibility, mold reusability, and improved clinical accessibility of custom prosthetics.