Polymers for conventional, subtractive, and additive manufacturing of occlusal devices differ in hardness and flexural properties but not in wear resistance

Polymeric Materials Used in 3DP in Dentistry-Biocompatibility Testing Challenges

In the latter part of the 20th century, remarkable developments in new dental materials and technologies were achieved. However, regarding the impact of dental resin-based materials 3D-printed on cellular responses, there have been a limited number of published studies recently. The biocompatibility of dental restorative materials is a controversial topic, especially when discussing modern manufacturing technologies. Three-dimensional printing generates the release of residual monomers due to incomplete polymerization of materials and involves the use of potentially toxic substances in post-printing processes that cannot be completely eliminated. Considering the issue of biocompatibility, this article aims to establish an overview of this aspect, summarizing the different types of biocompatibility tests performed on materials used in 3D printing in dentistry. In order to create this comprehensive review, articles dealing with the issue of 3D printing in dentistry were analysed by accessing the main specialized search engines using specific keywords. Relevant data referring to types of materials used in 3DP to manufacture various dental devices, polymerization methods, factors affecting monomer release, cytotoxicity of unreacted products or post-curing treatments, and methods for assessing biocompatibility were analysed. Although the introduction of new restorative materials used in dental treatments is subject to national and international regulations and standards, it is necessary to investigate them regarding biocompatibility in order to support or deny the manufacturers' statements regarding this aspect.

Mechanical performance of 3-dimensionally printed resins compared with conventional and milled resins for the manufacture of occlusal devices: A systematic review

STATEMENT OF PROBLEM

Digital methods for manufacturing occlusal devices provide advantages over conventional techniques, but information about the mechanical properties of 3-dimensionally (3D) printed resins is scarce.

PURPOSE

The purpose of this systematic review was to evaluate the literature to determine whether 3D-printed resins for occlusal devices present satisfactory mechanical performance when compared with milled and conventional heat polymerized and autopolymerized resins.

MATERIAL AND METHODS

This systematic review followed the guidelines of the Preferred Reporting Items for Systematic Reviews and Meta-Analyses (PRISMA) protocol and was registered in the Open Science Framework. The search strategy was applied without restriction of time and language to Embase, PubMed, Scopus, Science Direct, and Web of Science databases, and to the nonpeer-reviewed literature in ProQuest and Google Scholar. The selection process was conducted independently in 2 stages by 2 reviewers according to the eligibility criteria. The risk of bias was analyzed by using a checklist of important parameters to be considered. The systematic review considered the population, intervention, comparison, outcome, studies (PICOS) format, where population was resins for 3D printing of occlusal devices, intervention was inherent characteristics of the resin, comparison was conventional heat polymerized, autopolymerized, and milled resins, outcome was mechanical performance, and studies were in vitro experimental studies.

RESULTS

A total of 1430 articles were found with the search strategy. After removing 182 duplicates found in Rayyan, the title and abstract of 1248 articles were evaluated, of which 37 articles were screened from the databases, 23 were selected for full reading, and 6 met the eligibility criteria and were included in this review; 1 had a low risk of bias and 5 had a moderate risk. An additional search of the reference list of included articles did not result in the inclusion of any articles. A quantitative meta-analysis could not be performed because of the heterogeneity of the included studies regarding the type of resin used and the method for evaluating mechanical performance.

CONCLUSIONS

Resins for 3D printing had satisfactory mechanical performance for interocclusal devices when compared with conventional heat polymerized and autopolymerized resins, except for hardness. Milled resins were better than 3D-printed resins in hardness, wear resistance, flexural strength, flexural modulus, and fracture resistance when printing angle and thickness were not considered. Further development is needed in terms of printing techniques and chemical composition, as they are important for optimal mechanical properties and clinical performance.

Wear Behavior and Water Sorption of Additively Manufactured Resin-Based Splint Materials

3D printing as an additive manufacturing method has proven to be of great interest for the computerized production of oral splints. Various parameters must be taken into consideration when assessing the durability of oral splints in a wet environment, such as the mouth. The aim of this in vitro study was to assess the wear behavior and water sorption of two 3D-printed splint materials depending on their building orientation and post-processing parameters. The parameters considered included the type of post-polymerization and the type of cleaning utilized after printing. The average wear depth was between -421.8 μm and -667.5 μm. A significant influence of the building orientation (p < 0.001) but not of the material (p = 0.810), cleaning (p = 0.933), or post-polymerization (p = 0.237) on wear was demonstrated. The water sorption ranged between 13.8 μg/mm3 and 30.3 μg/mm3, featuring a significant dependency on material and building orientation but not on cleaning (p = 0.826) or post-polymerization (p = 0.343). Material and fabrication methods should be carefully selected, because the type of material and building orientation affect the wear and water sorption of additively manufactured splint materials.

Wear resistance of 3D printed occlusal device materials

STATEMENT OF PROBLEM

Three-dimensional (3D) printing offers an efficient method of producing occlusal devices; however, their wear resistance is poorly understood.

PURPOSE

The purpose of this in vitro study was to compare the wear resistance of flexible and rigid 3D printed occlusal device materials with milled and conventionally processed occlusal device materials.

MATERIAL AND METHODS

Blocks (n=8) of 3 flexible 3D printed materials (KeySplint Soft, NightGuard Flex 2, SmileGuard), 2 rigid 3D printed materials (KeySplint Hard, NightGuard Firm 2), 1 milled material (Ceramill A-Splint), 1 thermoform material (Erkoloc-Pro), 1 light-polymerized material (Eclipse Prosthetic Resin), 1 heat-polymerized material (Excel Formula Heat Cure Denture Base Material), and 1 autopolymerized material (Great Lakes Splint Resin Acrylic) were prepared and wet polished with 1200-grit SiC paper. The specimens were placed in a modified Alabama wear testing device with spherical zirconia antagonists. The devices applied a 20-N load and 2-mm horizontal slide for 400 000 cycles, and the test was run in a 33% glycerin solution. Following the wear test, the volumetric wear was measured with an optical profilometer. The Vickers microhardness of the materials was also measured (n=3). Volumetric wear and microhardness were compared with 1-way ANOVAs and Tukey post hoc analyses (α=.05).

RESULTS

Significant differences were found between the wear of the different occlusal device materials (P<.001). The rigid 3D printed materials experienced similar wear as the light-polymerized, heat-polymerized, and milled occlusal device materials. The autopolymerized and thermoformed occlusal device material experienced significantly more wear (P<.05). The flexible 3D printed materials had the significantly greatest wear (P<.05). A statistically significant, strong negative correlation between hardness and volumetric wear was found (r=-.93; P<.001).

CONCLUSIONS

Rigid 3D printed occlusal device materials exhibit a high degree of wear resistance; however, flexible 3D printed occlusal device materials exhibit relatively low wear resistance.

Comparative analysis of polishing protocols on microhardness and surface roughness of occlusal device materials fabricated using microwave-polymerized acrylic or 3D printed resins

STATEMENT OF PROBLEM

With advancements in digital technologies, the digital workflow has revolutionized the fabrication of occlusal devices through additive methods using 3-dimensional (3D) printing. However, an established protocol for polishing 3D printed occlusal devices is lacking, despite this step being crucial for minimizing surface porosity, material fatigue and preventing bacterial plaque accumulation, thereby contributing to device longevity.

PURPOSE

The purpose of this in vitro study was to evaluate the impact of polishing systems on the surface roughness and Vickers microhardness of heat-polymerizing acrylic resin and 3D printing resins used for occlusal devices.

MATERIAL AND METHODS

One hundred and twenty microwaved-polymerized acrylic resin and 3D printed resin specimens (40×40×3 mm) were divided into 12 groups (n=10) based on the type of resin and polishing protocol (Sealant, DhPro, Dhpro + Sealant, Trihawk, Trihawk + Sealant, and control). Surface roughness (Ra) and Vickers microhardness were tested. Additionally, 1 specimen per group underwent scanning electron microscopy before and after thermocycling (5000 cycles, 5 ºC and 55 ºC). Data analysis involved a 2-way ANOVA, 2-way repeated measured ANOVA, and Tukey's multiple comparison test (α=.05).

RESULTS

The Trihawk polishing protocol yielded significantly higher microhardness and lower surface roughness values for both resins. After thermocycling, the acrylic resin maintained its surface roughness for the Trihawk, Trihawk + Sealant, and unpolished groups, but all groups showed decreased microhardness. The 3D printing resin exhibited increased surface roughness and reduced microhardness after thermocycling across all groups.

CONCLUSIONS

The polishing protocol affects the surface microhardness and roughness of 3D printing resins and microwave acrylic resins for occlusal devices. Polishing using the Trihawk polishing protocol demonstrated significantly smoother and harder surfaces for both resins tested.

Effect of ethylene oxide unit number in bis-EMA on the physical properties of additive-manufactured occlusal splint material

PURPOSE

To investigate the effects of the number of ethylene oxide units in bis-EMA on the physical properties of additively manufactured occlusal splints.

METHODS

Seven experimental materials containing bis-EMAs with three and 10 ethylene oxide units (BE3 and BE10, respectively) were prepared at different BE10 content rates (BE10-0%, -20%, -30%, -40%, -50%, -60%, and -80%). Half the specimens of each material were aged in boiling water. Flexural strength (FS), flexural modulus (FM), fracture toughness (FT), microwear depth (MD), degree of conversion (DC), water sorption (WSP), water solubility (WSL), color difference between non-aged and aged series (ΔE), and translucency (TP) were evaluated. All the evaluated properties other than FS and MD were analyzed by 1-way ANOVA and Tukey's post hoc analysis, while FS and MD were analyzed by Kruskal-Wallis's test and Bonferroni correction (α=0.05).

RESULTS

BE10-80% revealed the lowest FS (P < 0.01 for BE10-0%, -20%, and -30%) and FM (P < 0.01, for all), while revealing the highest DC, WSP, WSL (P < 0.01 for all) and TP (P < 0.01 for all other than BE10-60%). BE10-50% showed the highest FT (P < 0.01 for all). BE10-50%, -60%, and -80% revealed significantly lower ΔE than others (P < 0.01) and lower MD than BE10-0% (P < 0.05). Regardless of the BE10 content, FS, FM, and FT decreased with aging.

CONCLUSIONS

The number of ethylene oxide units affects the physical properties of additively manufactured occlusal splints. The higher number of ethylene oxide units in bis-EMA enhanced the microwear resistance, DC, WSP, WSL, color stability, and translucency, whereas it deteriorated the FS and FM.

Effect of build orientation on the wear resistance and hardness of denture teeth fabricated using digital light processing: An in vitro study

PURPOSE

This in vitro study investigated the effect of build orientation on the wear resistance and hardness of denture teeth fabricated using digital light processing (DLP) compared to other denture tooth materials.

METHODS

Disc-shaped specimens were prepared using denture tooth monomers and DLP devices in three build orientations: 0°, 45°, and 90°. Specimens of the same shape were fabricated using denture tooth materials for subtractive manufacturing, commercially available polymethylmethacrylate (PMMA) resin, and composite resin. The wear resistance was evaluated as the wear volume loss after 50,000 wear cycles using a ball-on-disc wear device in water for two-body wear and poppy seed slurry for three-body wear. The Vickers hardness values of the materials were measured. Two-way and one-way analyses of variance were performed for wear resistance and hardness, respectively, followed by Tukey's honest significance test.

RESULTS

The interaction between the denture tooth resins and maximum wear volume was significant (P < 0.01). The 0° build orientation exhibited the lowest wear volume in the three-body wear test and the highest hardness among the three build orientations. The 0° DLP-fabricated specimens demonstrated significantly less wear volume than that of the PMMA specimens and a wear volume comparable to that of the milled specimens. However, the 0° DLP-fabricated specimens showed significantly lower hardness than that of the milled and PMMA specimens. The composite resin specimens exhibited the highest wear resistance and hardness.

CONCLUSIONS

A 0° build orientation is recommended for DLP-fabricated denture teeth compared to 45° and 90° orientations to achieve greater wear resistance and hardness.

Mechanical and physical properties of splint materials for oral appliances produced by additive, subtractive and conventional manufacturing

OBJECTIVES

To investigate the flexural strength (FS), elastic modulus (E), Martens hardness (HM), water sorption (wsp), water solubility (wsl) and degree of conversion (DC) of 3D-printed, milled and injection molded splint materials.

METHODS

Specimens (N = 1140) were fabricated from five 3D-printed (GR-22 flex, GR-10 guide, ProArt Print Splint clear, V-Print Splint, V-Print Splint comfort), five milled (BioniCut, EldyPlus, ProArt CAD Splint clear, Temp Premium Flexible, Thermeo) and two injection molded (PalaXPress clear, Pro Base Cold) materials. FS, E, HM, wsp, wsl and DC were tested initially (24 h, 37 °C, H2O), after water storage (90 d, 37 °C, H2O) as well as after thermal cycling (5000 thermal cycles, 5/55 °C). Data were analyzed with Kolmogorov-Smirnov, Kruskal- Wallis, Mann-Whitney U test and Spearman's correlation (p < 0.05).

RESULTS

Initially, the mean flexural strength values ranged from 1.9 to 90.7 MPa for printed, 3.8 to 107 MPa for milled and 99.7 to 102 MPa for injection molded materials. The initial mean elastic modulus values were 0.0 to 2.4 GPa for printed, 0.1 to 2.7 GPa for milled and 2.8 GPa for injection molded materials. The initial mean Martens hardness values were 14.5 to 126 N/mm2 for printed, 50.2 to 171 N/mm2 for milled and 143 to 151 N/mm2 for injection molded materials. Initially, the mean water sorption values ranged from 23.1 to 41.2 μg/mm3 for printed, 4.5 to 23.5 μg/mm3 for milled and from 22.5 to 23.3 μg/ mm3 for injection molded materials. The initial mean water solubility values ranged from 2.2 to 7.1 μg/mm3 for printed, 0.0 to 0.5 μg/mm3 for milled and 0.1 to 0.3 μg/mm3 for injection molded materials. After water storage and thermal cycling most of the values decreased and some increased. The mean DC values ranged initially from 72.3 to 94.5 %, after water storage from 74.2 to 96.8 % and after thermal cycling from 75.6 to 95.4 % for the printed materials.

SIGNIFICANCE

The mechanical and physical properties of printed, milled and injection molded materials for occlusal devices vary and are influenced by aging processes. For clinical applications, materials need to be chosen according to the specific indications.

The Influence of Thickness on the Mechanical Behaviors of 3D Printing Resins for Orthodontic Retainers

This study aimed to evaluate the mechanical behaviors of thermoformed and 3D-printed retainers with different thicknesses. Thermoformed retainers (Duran) and 3D-printed retainers (Dental LT Clear V2 and NextDent Ortho Flex) were fabricated at thicknesses of 0.5, 0.75, and 1 mm. Five samples of each material were subjected to compression, tensile, and flexural testing with the universal testing machine (Instron Ltd., Buckinghamshire, England). The results revealed that the mechanical behaviors were significantly influenced by thickness in each type of material. The increased thickness tended to increase strength and modulus in all three tests. However, Dental LT Clear V2 and Duran showed that flexural strength and modulus were inversely related to thickness. The compressive test revealed significantly greater compressive resistance in 3D-printed groups, except for the NextDent Ortho Flex at 0.5 mm. The tensile test showed that Dental LT Clear V2 at all thicknesses demonstrated significantly higher tensile strength and modulus, while NextDent Ortho Flex was significantly lowest at any thickness in tensile and flexural properties. In conclusion, the thickness significantly influenced the mechanical behaviors of the 3D-printed retainers. The 0.75 mm thickness of Dental LT Clear V2 could be considered as an alternative to fabricated retainers due to its similar mechanical properties compared with the thermoformed material.

Effect of material and antagonist type on the wear of occlusal devices with different compositions fabricated by using conventional, additive, and subtractive manufacturing

STATEMENT OF PROBLEM

Additive (AM) and subtractive (SM) manufacturing have become popular for fabricating occlusal devices with materials of different chemical compositions. However, knowledge on the effect of material and antagonist type on the wear characteristics of occlusal devices fabricated by using different methods is limited.

PURPOSE

The purpose of this in vitro study was to evaluate the effect of material and antagonist type on the wear of occlusal devices fabricated by using conventional manufacturing, AM, and SM.

MATERIAL AND METHODS

Two-hundred and forty Ø10×2-mm disk-shaped specimens were fabricated by using heat-polymerized polymethylmethacrylate (control, CM), AM clear device resin fabricated in 3 different orientations (horizontal [AMH], diagonal [AMD], and vertical [AMV]), SM polymethylmethacrylate (SMP), and SM ceramic-reinforced polyetheretherketone (SMB) (n=40). Specimens were then divided into 4 groups based on the antagonists: steatite ceramic (SC); multilayered zirconia (ZR); lithium disilicate (EX); and zirconia-reinforced lithium silicate (ZLS) used for thermomechanical aging (n=10). After aging, the volume loss (mm3) and maximum wear depth (μm) were digitally evaluated. Data were analyzed with 2-way analysis of variance and Tukey honestly significant difference tests (α=.05).

RESULTS

The interaction between the device material and the antagonist affected volume loss and maximum depth of wear (P<.001). AMH had volume loss and depth of wear that was either similar to or higher than those of other materials (P≤.044). When SC was used, CM had higher volume loss and depth of wear than AMV, and, when EX was used, AMD had higher volume loss and depth of wear than SMP (P≤.013). SC and ZR led to higher volume loss of CM and AMH than EX and led to the highest depth of wear for these materials, while ZR also led to the highest volume loss and depth of wear of AMD and AMV (P≤.019). EX led to the lowest volume loss and depth of wear of AMV and SMP and to the lowest depth of wear of AMH (P≤.021). Regardless of the antagonist, SMB had the lowest volume loss and depth of wear (P≤.005).

CONCLUSIONS

AMH mostly had higher volume loss and depth of wear, while SMB had the lowest volume loss, and its depth of wear was not affected by the tested antagonists. ZR mostly led to higher volume loss and maximum depth of wear, while EX mostly led to lower volume loss and maximum depth of wear of the tested occlusal device materials.

Wear resistance and flexural properties of low force SLA- and DLP-printed splint materials in different printing orientations: An in vitro study

OBJECTIVES

To investigate the influence of material and printing orientation on wear resistance and flexural properties of one low force SLA- and two DLP-printed splint materials and to compare these 3D-printed splints to a subtractively manufactured splint material.

METHODS

Two DLP-printed (V-Print splint, LuxaPrint Ortho Plus) and one low force SLA-printed (Dental LT Clear) material, where specimens were printed in three printing orientations (0°, 45°, 90°), were investigated. In addition, one milled splint material (Zirlux Splint Transparent) was examined. A total of 160 specimens were produced for both test series. The two-body wear test was performed in a chewing simulator (80'000 cycles at 50 N with 5-55 °C thermocycling). Steatite balls were used as antagonists. The wear pattern was analyzed with a 3D digital microscope in terms of maximum vertical intrusion depth (mm) and total volume loss (mm³). The flexural properties were investigated by three-point bending in accordance with ISO 20795-1: 2013 (denture base polymers). The flexural strength (MPa) and the flexural modulus (MPa) were measured. Two-way ANOVA was performed to investigate the effects of the two independent variables material and printing orientation for the three 3D-printed materials. The comparison of the printing orientations within one material was carried out with one-way ANOVA with post-hoc Tukey tests.

RESULTS

Two-way ANOVA revealed that wear and flexural properties are highly dependent on the 3D-printed material (p < 0.001). Across groups, a significant effect was observed for wear depth (p = 0.031) and wear volume (p = 0.044) with regard to printing orientation but this was not found for flexural strength (p = 0.080) and flexural modulus (p = 0.136). One-way ANOVA showed that both DLP-printed groups showed no significant differences within the printing orientations in terms of wear and flexural properties. Dental LT Clear showed that 90° oriented specimens had higher flexural strength than 0° oriented ones (p < 0.001) and 45° oriented specimens also showed higher values than 0° ones (p = 0.038). No significant differences were observed within the printing orientations for flexural modulus and wear behaviour within this group. T-tests showed that the milled splints exhibited statistically higher wear resistance and flexural properties compared to all three 3D-printed splint materials (p < 0.001) and that highly significant differences were found between the 3D-printed splint materials for both test series.

CONCLUSION

Within the limitations of this in vitro study, it can be stated that wear behaviour and flexural properties are highly dependent on the 3D-printed material itself. Currently, milled splints exhibit higher wear resistance and flexural properties compared to 3D-printed splint materials. The printing orientation has a minor influence on the properties investigated. Nevertheless, two-way ANOVA also showed a significant influence of printing orientation in the wear test across groups and one-way ANOVA detected significant effects for SLA material in terms of flexural strength, with printing in 90° showing the highest flexural strength. Therefore, anisotropy was found in SLA material, but it can be limited with the employed printing parameters. Both DLP-printed materials showed no significant difference within the printing orientation.

Materials and Applications of 3D Printing Technology in Dentistry: An Overview

PURPOSE

This narrative review aims to provide an overview of the mechanisms of 3D printing, the dental materials relevant to each mechanism, and the possible applications of these materials within different areas of dentistry.

METHODS

Subtopics within 3D printing technology in dentistry were identified and divided among five reviewers. Electronic searches of the Medline (PubMed) database were performed with the following search keywords: 3D printing, digital light processing, stereolithography, digital dentistry, dental materials, and a combination of the keywords. For this review, only studies or review papers investigating 3D printing technology for dental or medical applications were included. Due to the nature of this review, no formal evidence-based quality assessment was performed, and the search was limited to the English language without further restrictions.

RESULTS

A total of 64 articles were included. The significant applications, applied materials, limitations, and future directions of 3D printing technology were reviewed. Subtopics include the chronological evolution of 3D printing technology, the mechanisms of 3D printing technologies along with different printable materials with unique biomechanical properties, and the wide range of applications for 3D printing in dentistry.

CONCLUSIONS

This review article gives an overview of the history and evolution of 3D printing technology, as well as its associated advantages and disadvantages. Current 3D printing technologies include stereolithography, digital light processing, fused deposition modeling, selective laser sintering/melting, photopolymer jetting, powder binder, and 3D laser bioprinting. The main categories of 3D printing materials are polymers, metals, and ceramics. Despite limitations in printing accuracy and quality, 3D printing technology is now able to offer us a wide variety of potential applications in different fields of dentistry, including prosthodontics, implantology, oral and maxillofacial, orthodontics, endodontics, and periodontics. Understanding the existing spectrum of 3D printing applications in dentistry will serve to further expand its use in the dental field. Three-dimensional printing technology has brought about a paradigm shift in the delivery of clinical care in medicine and dentistry. The clinical use of 3D printing has created versatile applications which streamline our digital workflow. Technological advancements have also paved the way for the integration of new dental materials into dentistry.

Aging Processes and Their Influence on the Mechanical Properties of Printable Occlusal Splint Materials

Three-dimensional (3D)-printed occlusal splints are becoming more prevalent in the treatment of tooth substance loss due to their fast and cost-effective production. The purpose of this in vitro study was to investigate whether the mechanical properties (tensile strength-TS, modulus of elasticity in tension-ME, and Vickers hardness-HV) vary between the materials (printed dimethacrylate-based resins: Keyprint KeySplint soft-KEY, Luxaprint Ortho Plus-LUX, V-Print splint-VPR, printed methacrylate-based resins Freeprint splint 2.0-FRE, and milled methacrylate-based material, CLEAR splint-CLE), and the influence of aging processes (extraoral storage conditions and nightly or daily use) was examined. The printed methacrylate-based resins (FRE, LUX, and VPR) had much higher TS (43.7-48.5 MPa compared to 12.3-13.3 MPa), higher ME (2.01-2.37 GPa compared to 0.43-0.72 GPa), and higher HV (11.8-15.0 HV compared to 3.3-3.5 HV) than both of the methacrylate-based resins (KEY and CLE) after the production process. Although the TS, ME, and HV of the printed dimethacrylate resins (FRE, LUX, and VPR) decreased significantly under humid conditions with possibly elevated temperatures (thermocycling as well as 37 °C), these mechanical properties were significantly higher than both methacrylate-based resins (KEY and CLE). Therefore, printed dimethacrylate resins should be used rather than methacrylate-based resins for high expected masticatory forces, low wall thicknesses, or very long wearing times (≥6 months).

Evaluation of enamel wear by 3 occlusal splint materials: An in vitro study

STATEMENT OF PROBLEM

Occlusal devices used to manage bruxism have been commonly fabricated from polymethyl methacrylate with the powder-liquid technique. More recently, Vertex ThermoSens (VTS) and the biocompatible high-performance polymer (BioHPP), an optimized material having polyetheretherketone (PEEK) as its basis, have been used, but little is known about the wear of these materials on human enamel.

PURPOSE

The purpose of this in vitro study was to assess via a mastication simulation test how 3 occlusal device materials affected the wear and roughness of enamel antagonists.

MATERIAL AND METHODS

A noncontact 3D optical profilometer was used to measure the enamel surface roughness (Ra) against 3 occlusal device materials: vertex regular, VTS, and PEEK high-performance polymer (BioHPP). A dual-axis mastication simulator was used to perform a 2-body wear test on specimens from each group. The test consisted of 10 000 cycles with a 70-N force and 5 to 55 °C thermocycling. Following simulated mastication, the weight of each specimen and the Ra change were compared with the Kolmogorov-Smirnov test, paired specimens t test, Wilcoxon signed-rank test, and 1-way analysis of variance (α=.05).

RESULTS

The polyamide group caused the lowest amount of enamel wear (P<.05), while the heat-polymerized acrylic resin group induced the largest amount of enamel wear (P<.05). For polyamide and PEEK, the change in enamel surface roughness exhibited a smooth texture, whereas it found a rougher surface for the heat-polymerized acrylic resin.

CONCLUSIONS

According to this study, surface roughness and wear on human enamel were not correlated. PEEK is a promising material for the fabrication of occlusal devices.

Method development for the intraoral release of nanoparticles from dental restorative materials

OBJECTIVE

The aim of this study was the development of a novel in-vitro method to evaluate the intraoral release of wear particles with a diameter< 1 µm from dental restorative materials.

METHODS

Test fixtures for a dual-axis chewing simulator (CS-4.8, SD Mechatronik, Feldkirchen-Westerham, Germany), consisting of three components to mount the specimens and a solvent (distilled water) as well as a zirconia antagonist to transfer the masticatory forces onto the specimen was developed. Ceram.x Spectra™ ST HV (CS) and Filtek™ Supreme XTE (FS) specimens (n = 3) were fixed into the mounts and immersed in 25 ml solvent. All specimens were subjected to 500.000 wear cycles with a load of 49 N. The particle size distribution of the suspensions were examined by dynamic light scattering (DLS). The collected particles were characterised by scanning electron microscopy (SEM) and energy dispersive spectroscopy (EDS). For wear quantification, the surfaces of the specimens were photo-optically scanned and the wear was measured. For the statistical analysis, one-way ANOVA and post-hoc Scheffé tests were applied.

RESULTS

DLS showed particle diameters< 1 µm (CS: 18.06 nm-1.64 µm, FS: 72.30 nm-2.31 µm). SEM/EDS indicated an association between the detected elements and the materials' composition. FS showed significantly higher volume loss (p = 0.007) and maximum depth of the wear profile (p = 0.005) than CS, but no significant differences in the surface loss (p = 0.668).

SIGNIFICANCE

The novel method is able to detect material dependent particles to the size of nanoscale after in-vitro abrasion.

3D Printing of Dental Prostheses: Current and Emerging Applications

Revolutionary fabrication technologies such as three-dimensional (3D) printing to develop dental structures are expected to replace traditional methods due to their ability to establish constructs with the required mechanical properties and detailed structures. Three-dimensional printing, as an additive manufacturing approach, has the potential to rapidly fabricate complex dental prostheses by employing a bottom-up strategy in a layer-by-layer fashion. This new technology allows dentists to extend their degree of freedom in selecting, creating, and performing the required treatments. Three-dimensional printing has been narrowly employed in the fabrication of various kinds of prostheses and implants. There is still an on-demand production procedure that offers a reasonable method with superior efficiency to engineer multifaceted dental constructs. This review article aims to cover the most recent applications of 3D printing techniques in the manufacturing of dental prosthetics. More specifically, after describing various 3D printing techniques and their advantages/disadvantages, the applications of 3D printing in dental prostheses are elaborated in various examples in the literature. Different 3D printing techniques have the capability to use different materials, including thermoplastic polymers, ceramics, and metals with distinctive suitability for dental applications, which are discussed in this article. The relevant limitations and challenges that currently limit the efficacy of 3D printing in this field are also reviewed. This review article has employed five major scientific databases, including Google Scholar, PubMed, ScienceDirect, Web of Science, and Scopus, with appropriate keywords to find the most relevant literature in the subject of dental prostheses 3D printing.

Evaluation of the mechanical properties of different materials for manufacturing occlusal splints

This study aimed to compare the mechanical properties of various occlusal plate materials by analyzing surface roughness, Knoop microhardness, flexural strength, and modulus of elasticity. Fifty samples were prepared and classified as SC (self-curing acrylic resin), WB (heat-cured acrylic resin), ME (acrylic resin polymerized by microwave energy), P (resin print), and M (polymethylmethacrylate polymer block for computer-aided design/computer-aided manufacturing). The data were analyzed using a one-way analysis of variance and Tukey's honestly significant difference test. Surface roughness was the same in all groups. The surface hardness of group M was statistically superior. The samples from groups P and M had higher flexural strength than other samples. The modulus of elasticity of group SC was statistically lower than that of other groups. The mechanical properties of the materials used to make the occlusal plates differed, and group M achieved the best results in all analyses. Therefore, clinicians must consider the material used to manufacture long-lasting and efficient occlusal splints.

Implementation of a Full Digital Workflow by 3D Printing Intraoral Splints Used in Dental Education: An Exploratory Observational Study with Respect to Students' Experiences

Fully digital workflows gained acceptance in dental practice and thereby are of interest for undergraduate education. An exploratory clinical observation was designed to track the implementation of such a workflow with novice digital users in order to describe its feasibility, time investment, and pitfalls.

METHODS

Students were invited to provide feedback for their experiences with a training module that consisted of the following: intraoral scanning, computer-aided design (CAD), manual finishing, and insertion of a 3D-printed bite splint for the lower jaw.

RESULTS

A total of 82 fourth-year students participated in the module. The average time required to perform an intraoral scan was 17 m 5 s, and all students were able to design a splint with an average time of 2 h 38 m. Students who indicated prior experience with CAD seem to outperform inexperienced students in both CAD task completion and intraoral scanning. The initial fit was reported as clinically acceptable by 68.5% of the participants, while 79% rated the workflow as very good to satisfactory and indicated that the training was helpful for dental practice.

CONCLUSIONS

The implementation of a digital workflow in undergraduate dental education is feasible and has acceptable clinical results. However, CAD is time-intensive, and the experience can be challenging.

Development of Bisphenol-A-Glycidyl-Methacrylate- and Trimethylolpropane-Triacrylate-Based Stereolithography 3D Printing Materials

The main advantages of the three-dimensional (3D) printing process are flexible design, rapid prototyping, multi-component structures, and minimal waste. For stereolithography (SLA) 3D printing, common photocurable polymers, such as bisphenol-A glycidyl methacrylate (Bis-EMA), trimethylolpropane triacrylate (TMPTMA), as well as urethane oligomers, have been widely used. For a successful 3D printing process, these photocurable polymers must satisfy several requirements, including transparency, a low viscosity, good mechanical strength, and low shrinkage post-ultraviolet curing process. Herein, we investigated SLA-type photocurable resins prepared using Bis-EMA, TMPTMA, and urethane oligomers. The flexural strength, hardness, conversion rate, output resolution, water absorption, and solubility of the printed materials were investigated. The degree of conversion of the printed specimens measured by infrared spectroscopy ranged from 30 to 60%. We also observed that 64-80 MPa of the flexural strength, 40-60 HV of the surface hardness, 15.6-29.1 MPa of the compression strength, and 3.3-14.5 MPa of the tensile strength. The output resolution was tested using three different structures comprising a series of columns (5-50 mm), circles (0.6-6 mm), and lines (0.2-5 mm). In addition, we used five different pigments to create colored resins and successfully printed complex models of the Eiffel Tower. The research on resins, according to the characteristics of these materials, will help in the design of new materials. These results suggests that acrylate-based resins have the potential for 3D printing.

Pierre Robin Sequence and 3D Printed Personalized Composite Appliances in Interdisciplinary Approach

This paper introduces a complex novel concept and methodology for the creation of personalized biomedical appliances 3D-printed from certified biocompatible photopolymer resin Dental LT Clear (V2). The explained workflow includes intraoral and CT scanning, patient virtualization, digital appliance design, additive manufacturing, and clinical application with evaluation of the appliance intended for patients with cranio-facial syndromes. The presented concept defines virtual 3D fusion of intraoral optical scan and segmented CT as sufficient and accurate data defining the 3D surface of the face, intraoral and airway morphology necessary for the 3D design of complex personalized intraoral and extraoral parts of the orthopedic appliance. A central aspect of the concept is a feasible utilization of composite resin for biomedical prototyping of the sequence of marginally different appliances necessary to keep the pace with the patient rapid growth. Affordability, noninvasiveness, and practicality of the appliance update process shall be highlighted. The methodology is demonstrated on a particular case of two-year-old infant with Pierre Robin sequence. Materialization by additive manufacturing of this photopolymer provides a highly durable and resistant-to-fracture two-part appliance similar to a Tübingen palatal plate, for example. The paper concludes with the viability of the described method and material upon interdisciplinary clinical evaluation of experts from departments of orthodontics and cleft anomalies, pediatric pneumology and phthisiology, and pediatric otorhinolaryngology.

Comparison of Wear of Interim Crowns in Accordance with the Build Angle of Digital Light Processing 3D Printing: A Preliminary In Vivo Study

The aim of this study is to evaluate the wear volume of interim crowns fabricated using digital light processing 3D printing according to the printing angle. A total of five patients undergoing the placement of a single crown on the mandibular molar were included. Interim crowns were fabricated directly in the oral cavity using the conventional method. A digital light processing 3D printer was then used to fabricate crowns with build angles of 0, 45, and 90 degrees. Therefore, four fabricated interim crowns were randomly delivered to the patients, and each was used for one week. Before and after use, the intaglio surfaces of the interim crowns were scanned using a 3D scanner. The volume changes before and after use were measured, and changes in the height of the occlusal surface were evaluated using the root mean square value. Data normality was verified by statistical analysis, and the wear volume in each group was evaluated using a one-way analysis of variance and Tukey’s honestly significant difference test (α = 0.05). Compared with the RMS values of the conventional method (11.88 ± 2.69 µm) and the 3D-printing method at 0 degrees (12.14 ± 2.38 µm), the RMS values were significantly high at 90 degrees (16.46 ± 2.39 µm) (p < 0.05). Likewise, there was a significant difference in the change in volume between the groups (p = 0.002), with a significantly higher volume change value at 90 degrees (1.74 ± 0.41 mm3) than in the conventional method (0.70 ± 0.15 mm3) (p < 0.05). A printing angle of 90 degrees is not recommended when interim crowns are fabricated using digital light processing 3D printing.

Two-body wear of occlusal splint materials from subtractive computer-aided manufacturing and three-dimensional printing

OBJECTIVES

To investigate the two-body wear of occlusal splint materials fabricated from subtractive computer-aided manufacturing (CAM) compared to three-dimensional printing (3DP).

MATERIAL AND METHODS

Forty-eight substrates (n = 12/material) in the design of a mandibular first molar were fabricated using CAM (CAM-TD, Thermeo, pro3dure medical GmbH, Iserlohn, Germany; CAM-CL, CLEARsplint, Astron Dental Corporation, Lake Zurich, USA) and 3DP (3DP-GI, GR22 flex, pro3dure medical GmbH; 3DP-KY, KeySplint soft, Keystone Industries, Gibbstown, USA). The substrates were subjected to mastication simulation (120,000 cycles, 37 °C, 50 N, 1.3 Hz) opposed to enamel antagonists. The two-body wear was measured through matching of the scanned substrates before and after aging using Gaussian best-fit method. The damage patterns were categorized and evaluated based on microscopic examinations. Data was analyzed using Kolmogorov-Smirnov test followed by 1-way analysis of variance (ANOVA). Pearson correlation was calculated between vertical and volumetric material loss. The failure types were analyzed with Chi²-test and Ciba Geigy table.

RESULTS

No difference in two-body wear results between all materials was found (p = 0.102). Fatigue substrates showed a perforation for CAM and a fracture for 3DP. No abrasion losses on the antagonists were detected.

CONCLUSIONS

3DP substrates showed no differences in two-body wear compared to CAM ones but are more likely to show a fracture. None of the tested materials caused an abrasion on human teeth structure.

CLINICAL RELEVANCE

While therapies with occlusal splint materials are rising, 3DP offers a promising alternative to CAM in terms of production accuracy and therapeutic success at reduced costs.

Accuracy of 3D-Printed Occlusal Devices of Different Volumes Using a Digital Light Processing Printer

(1) Background: This in-vitro study was designed to investigate the accuracy of CAD/CAM fabricated occlusal devices with different heights and volumes. (2) Methods: Based on an intraoral scan, an occlusal device with a vertical bite elevation of 2.5 mm and 4.5 mm was digitally designed and 3D printed 10 times. The fabricated occlusal devices were digitized by an industrial structured light scanner (ILS) and provided in stl-format as test objects. The test objects were superimposed with the design dataset as reference to evaluate the accuracy of complete surfaces ([2.5_TOTAL] and [4.5_TOTAL]) with respect to their internal surfaces ([2.5_INTERNAL] and [4.5_INTERNAL]). The mean trueness and precision were calculated based on absolute mean deviation. Absolute and relative volume differences between reference and test were computed. Statistical significances were analyzed performing the Wilcoxon test (α = 0.05). (3) Results: As absolute mean deviation trueness values were obtained: 59 ± 5 µm for [2.5_INTERNAL], 98 ± 9 µm for [4.5_INTERNAL], 68 ± 1 µm for [2.5_TOTAL] and 90 ± 10 µm for [4.5_TOTAL]. The precision applying absolute mean deviation was 14 ± 8 µm for [2.5_INTERNAL], 22 ± 11 µm for [4.5_INTERNAL], 19 ± 10 µm for [2.5_TOTAL] and 26 ± 13 µm for [4.5_TOTAL]. The mean trueness and precision values differed significantly. Volume differences of 2.11% for [4.5_TOTAL] and of 2.35% for [2.5_TOTAL] in comparison to their reference file were evaluated. (4) Conclusions: Printed occlusal devices with minor height and volume were more accurate. Both types of devices exhibited results that were comparable to the literature.

In Vitro Time Efficiency, Fit, and Wear of Conventionally- versus Digitally-Fabricated Occlusal Splints

The purpose of the study was to compare conventional to digital workflows of occlusal splint production regarding time efficiency, overall fit, and wear. Fifteen Michigan splints were fabricated with a conventional and digital method. The duration for the dentist's and the dental technician's workload was recorded. Subsequently, the overall fit was examined with a four-level score (1-4). Paired t-tests were used to compare the time results for the conventional and digital workflows and the sign test to compare the overall fit. The mean time (16 min 58 s) for computerized optical impressions was longer than for conventional impressions (6 min 59 s; p = 0.0001). However, the dental technician needed significantly less mean time for the digital splint production (47 min 52 s) than for the conventional (163 min 32 s; p = 0.001). The overall fit of the digitally-fabricated splints was significantly better compared to the conventionally-fabricated splints (p = 0.002). There was no impact of the different materials used in the conventional and digital workflow on the wear (p = 0.26). The results suggest that the digital workflow for the production of occlusal splints is more time efficient and leads to a better fit than the conventional workflow.

Wear Behavior of Occlusal Splint Materials Manufactured By Various Methods: A Systematic Review

PURPOSE

To systematically review studies on various materials and methods used for wear testing of occlusal devices and their antagonists in vitro and in vivo.

METHODS

An electronic search in OVID, Web of Science, PubMed and Scopus was conducted using the following terms (MeSH words) with any synonyms and closed terms: "Splint*" OR "occlusal splint*" OR "night guard" OR "occlusal device" OR "occlusal devices" OR "deprogrammer" OR "bite splint" OR "bite plane" OR "orthotic appliance*" OR "orthotic devices" AND "wear" OR "two-body wear" OR "three-body wear" OR "tooth wear" OR "wear measurement*" OR "wear behaviour" OR "wear behavior" OR "abrasion" AND "Polymethyl Methacrylate" OR "PMMA" OR "acrylic resin*" OR "dental material*" OR "dental enamel" OR "CAD" OR "CAM" OR "PEEK" OR "material* testing". Database search was limited to English-language publications and published between 2001 and 1st of September 2021. A further hand search was done to ensure all materials were captured.

RESULTS

After the removal of duplicates, 115 studies were identified, and 11 were chosen for review. Studies showed that the lowest volumetric loss was observed in PEEK occlusal device materials, whereas heat-cure, CAD-milled, and 3D printed occlusal device materials had no significant difference in wear. Vacuum-formed materials showed the highest wear among all groups. Testing parameters were found to be inconsistent across all studies.

CONCLUSION

There is a need for standardization of in vitro and in vivo wear measurement and testing protocols as this study revealed a wide variety of testing protocols which potentially could influence the outcome. Polishing procedures are required for the material. Limited studies are available on 3D printed occlusal device materials and would therefore require further investigation, especially on printing build angles and settings. Further clinical studies would be advantageous to provide guidance on the selection of the best occlusal device material that would last the longest without remake.

Effect of Artificial Aging on Mechanical and Tribological Properties of CAD/CAM Composite Materials Used in Dentistry

With easy-to-process 3D printing materials and fast production, the quality of dental services can be improved. In the conventional procedure, the dentist makes temporary crowns directly in the patient’s mouth, e.g., from the most commonly used bis-acrylic composites. Temporary crowns made directly in the office without the use of CAD/CAM are often of inferior quality, which directly results in impaired hygiene, poorer masticatory mechanics, greater deposition of plaque, calculus and sediment, and may adversely affect periodontal and gum health. The mechanical strength, resistance to aging and abrasion of 3D printing materials are higher than those of the soft materials used in conventional methods. This translates into durability. The patient leaves the surgery with a restoration of higher utility quality compared to the conventional method. The objective of the paper was to determine the influence of aging in artificial saliva of AM (additive manufacturing) orthodontic composites on their functional properties. For the purpose of the study, fillings well-known worldwide were selected. These were traditional UV-curable resins (M I, M II, M III, M V) and a hybrid material based on a UV-curable resin (M VI). Samples were stored in artificial saliva at 37 ± 1 °C in a thermal chamber for 6 months. Indentation hardness, frictional tests and sliding wear measurements were conducted. A comparison between various materials was made. Descriptive statistics, degradation coefficients, H²E, Archard wear and specific wear rate were calculated. The Weibull statistical test for indentation hardness was performed and Hertzian contact stresses for the frictional association were calculated for unaged (M I, M II, M III, M V, M VI) and aged (M I AS, M II AS, M III AS, M V AS, M VI AS) samples. M I exhibited the lowest average hardness among the unaged materials, while M III AS had the lowest average hardness among the aged materials. Comparably low hardness was demonstrated by the M I AS material. The coefficient of friction values for the aged samples were found to be higher. The lowest wear value was demonstrated by the M I material. The wear resistance of most of the tested materials deteriorated after aging. The M VI AS material had the highest increase in wear. According to the results provided, not only the chemical composition and structure, but also aging have a great impact on the indentation hardness and wear resistance of the tested orthodontic materials.