Accidental Use of Plaster in Dental Impression Leading to Metal Tray Retention

Abstract

Dental impression materials are used for capturing the characteristics of intraoral structures and producing hard and soft tissue models for dental prostheses, orthodontic appliances, and other clinical purposes. Preparation of these materials must strictly follow the manufacturer’s instructions in order to preserve their properties and ensure a predictable clinical outcome. A 20-year-old man presented to the Emergency Department of a tertiary hospital with an inability to remove a metal impression tray retained in the maxilla for approximately 15 hours. The incident occurred during a home impression procedure in which dental plaster was mistakenly used instead of alginate, owing to their similar appearance. Clinical examination revealed a closed metal tray embedded in the upper arch containing hardened plaster. The tray was sectioned bilaterally using a diamond turbine bur, and the hardened plaster was subsequently removed with a handpiece and carbide bur. No injury to the teeth or oral mucosa was observed, and follow-up examinations at one and five months confirmed intact oral tissues with preserved tooth sensitivity. This case illustrates the importance of adherence to the manufacturer’s instructions, professional supervision, and controlled clinical environments during dental impression procedures. To the authors’ knowledge, this is the first reported case of this specific complication.