Analog and digital complete denture bases accuracy and dimensional stability: An in-vitro evaluation at 24 hours and 6 months

The study aimed to evaluate the accuracy of 3D printed complete denture bases compared to analog and milling manufacturing. Denture bases (n = 60) were created using three methods: milling (n = 10), analog (flasking) (n = 10), and 3D printing (n = 40). The 3D printing group was further divided into...

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Published in:Journal of dentistry Vol. 157; p. 105658
Main Authors: Casucci, Alessio, Verniani, Giulia, Bonadeo, Giovanni, Fadil, Sahin, Ferrari, Marco
Format: Journal Article
Language:English
Published: England Elsevier Ltd 01.06.2025
Subjects:
3D printing
Accuracy
Acrylic Resins - chemistry
Computer-Aided Design
Dental Materials - chemistry
Denture bases
Denture Bases - standards
Denture Design - methods
Denture, Complete
Humans
Imaging, Three-Dimensional
Materials Testing
Milling
Printing, Three-Dimensional
RMS values
Surface Properties
Time Factors
RMS values
Accuracy
Denture bases
3D printing
Milling
ISSN:0300-5712, 1879-176X, 1879-176X
Online Access:Get full text
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Summary:The study aimed to evaluate the accuracy of 3D printed complete denture bases compared to analog and milling manufacturing. Denture bases (n = 60) were created using three methods: milling (n = 10), analog (flasking) (n = 10), and 3D printing (n = 40). The 3D printing group was further divided into subgroups and each of the material groups. All samples were scanned, and their surfaces were analyzed using 3D software (Geomagic Control X software, 3D Systems) to compare them to the reference model. The accuracy was assessed using root mean square (RMS) values, reflecting the average deviation between the denture bases and the reference model. At 24 h, the "Temp Print", from 3D printing group had the lowest RMS values (54.20±9.44 µm), indicating higher accuracy, while the "ProBase Hot" from the anlog group showed the highest discrepancies, particularly in the border areas. Over six months, all groups experienced increased RMS values, with the 3d pronted "Denture 3d+" group showing the most significant variations (194.1 ± 49.63 µm). The "Temp Print" group maintained the lowest RMS values, indicating better stability at 6 months. Despite some discrepancies, all denture bases remained within clinically acceptable limits (300 µm). Milled bases were the most stable between 24 h and six months. In terms of accuracy and stability, 3D printed resins are suitable for both prototypes and definitive dentures. Further research is required to confirm the clinical acceptability of these materials. Accuracy in the fabrication of denture bases is paramount for ensuring proper fit, function, and comfort for patients. Analog, addictive and subtractive manufacturing methods of production obtained good dentures accuracy.
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ISSN:0300-5712
1879-176X
1879-176X
DOI:10.1016/j.jdent.2025.105658