Comparison of Dimensional Changes Between CAD-CAM Milled Complete Denture Bases and 3D Printed Complete Denture Bases: An In Vitro Study

Influence of impression method and shoulder design on the marginal adaptation of CAD/CAM nanoceramic resin onlay restorations

Objective

This in-vitro study investigates the influence of two different impression techniques and two shoulder designs on the marginal adaptation of computer-aided design/computer-aided manufacturing restorations.

Methods

Forty mandibular first premolars were cast into dental arch models for this in vitro study. Fragile cusps and concavities on the mesial-buccal-occlusal surfaces were treated, with 2 mm of the occlusal surface removed. Teeth were categorised into two groups based on shoulder preparation. Digital scanning using a 3Shape 3D scanner identified them further for allocation into conventional and digital impression subgroups. The restorations were created from nanoceramic resin blocks using prescribed guidelines. Microscopic evaluation assessed the restoration's marginal adaptation, with data analysed using SPSS 27.0. The level of significance was set at p ≤ 0.05.

Results

Digital intraoral scanning consistently demonstrated smaller marginal gaps than the traditional impression method, regardless of shoulder preparation, with the differences being statistically significant (p < 0.05). Furthermore, shoulder preparation significantly reduced the marginal gaps in both the digital and traditional impression groups (p < 0.05).

Conclusions

The onlay preparation design with a shoulder led to restorations with improved marginal adaptation compared with the design with no shoulder. Direct digital impression techniques produced restorations within a better marginal discrepancy than traditional impressions.

Evaluation of the effect of thermocycling on the trueness and precision of digitally fabricated complete denture bases

BACKGROUND

While many denture base materials are currently available on the market, little data exists regarding their dimensional stability after exposure to the oral environment. This study aimed to evaluate the effect of thermocycling on the trueness and precision of milled, 3-dimensional (3D)-printed, and conventional digitally fabricated complete denture bases (CDBs).

METHODS

A completely edentulous maxillary stone model was scanned to generate a standard tessellation language (STL) file; this was imported into metal-milling-machine software (Redon Hybrid CAD-CAM metal milling machine, Redon, Turkey) to produce a metal model for fabricating 30 CDBs. These were divided into three groups (n = 10 in each) according to the construction technique: group 1, CAD-CAM milled CDBs; group 2, 3D-printed CDBs; and group 3, conventional compression molded CDBs. All CDBs were scanned after fabrication and evaluated before and after thermocycling using superimposition. The data were analyzed using a one-way ANOVA, Tukey's post hoc test, and a paired t-test.

RESULTS

The level of trueness between the CAD-CAM milled, 3D-printed, and compression molded CDBs showed significant differences before and after thermocycling (P < 0.05). Group 1 showed the highest degree of trueness before and after thermocycling, group 3 exhibited a higher degree of trueness than group 2 before thermocycling, and group 2 had a higher degree of trueness than group 3 after thermocycling. There was a significant difference in the precision for each CDB type before and after thermocycling (P < 0.05).

CONCLUSION

The trueness of the CAD-CAM milling system in complete denture (CD) fabrication is superior to that of the 3D printing and conventional compression molding systems before and after thermocycling. Thermocycling had a significant effect on the precision of all CDB types. The compression molding system in CD construction is the most negatively affected via thermocycling with regard to the measures of trueness and precision.

CLINICAL TRIAL NUMBER

Not applicable, no human participants were involved.

Digitally designed and milled implant-retained maxillofacial prosthesis for velopharyngeal closure in a patient with a nonsurgically treated cleft palate: A clinical report

An implant-retained maxillofacial overdenture with a pharyngeal speech aid prosthesis was fabricated for a patient with a nonsurgically treated cleft palate who was unable to achieve velopharyngeal closure. Computer-aided design and computer-aided manufacturing were used to fabricate a metal-reinforced prosthesis using the Ivotion Denture System and subtractive manufacturing with geographic guides. Magnetic attachments were incorporated to improve the retention and stability of the prosthesis. Masticatory function, deglutition, and esthetics were found to be improved at the 6-month follow-up.

The effect of various surface treatments on the repair bond strength of denture bases produced by digital and conventional methods

There is limited information on the repairability of prostheses produced with digital technology. This study aims to evaluate various surface treatments on flexural bond strength of repaired dentured base resins produced by digital and conventional methods. A total of 360 samples were prepared from one heat-polymerized, one CAD/CAM milled and one 3D printed denture base materials. All of the test samples were subjected to thermocycling (5-55 °C, 5000 cycles) before and after repair with auto-polymerizing acrylic resin. The test samples were divided into five subgroups according to the surface treatment: grinding with silicon carbide (SC), sandblasting with Al2O3 (SB), Er:YAG laser (L), plasma (P) and negative control (NC) group (no treatment). In addition, the positive control (PC) group consisted of intact samples for the flexural strength test. Surface roughness measurements were performed with a profilometer. After repairing the test samples, a universal test device determined the flexural strength values. Both the surface topography and the fractured surfaces of samples were examined by SEM analysis. The elemental composition of the tested samples was analyzed by EDS. Kruskal-Wallis and Mann-Whitney U tests were performed for statistical analysis of data. SB and L surface treatments statistically significantly increased the surface roughness values of all three materials compared to NC subgroups (p < 0.001). The flexural strength values of the PC groups in all three test materials were significantly higher than those of the other groups (p < 0.001). The repair flexural strength values were statistically different between the SC-SB, L-SB, and NC-SB subgroups for the CAD/CAM groups, and the L-SC and L-NC subgroups for the 3D groups (p < 0.001). The surface treatments applied to the CAD/CAM and heat-polymerized groups did not result in a statistically significant difference in the repair flexural strength values compared to the NC groups (p > 0.05). Laser surface treatment has been the most powerful repair method for 3D printing technique. Surface treatments led to similar repair flexural strengths to untreated groups for CAD/CAM milled and heat-polymerized test samples.

Effect of Duplication Techniques on the Fitting Accuracy of CAD-CAM Milled, 3D-Printed, and Injection-Molded Mandibular Complete Denture Bases

BACKGROUND

Digital technology has been introduced in prosthodontics, and it has been widely used in denture duplication instead of a conventional denture duplication technique. However, research comparing different denture duplication techniques and how they affect the fitting accuracy of the denture base is scarce.

OBJECTIVES

The aim was to assess the impact of duplication techniques on the accuracy of the fitting surface of computer-aided design and manufacturing (CAD-CAM) milled, 3D-printed, and injection-molded complete denture bases (CDBs).

METHODOLOGY

This study involved fabricating a mandibular complete denture base with three marked dimples as reference marks (A, B, and C at the incisive papilla, right molar, and left molar areas) using a conventional compression molded technique. This denture was then scanned to generate a standard tessellation language (STL) file; after that, it was duplicated using three different techniques (milling, 3D printing, and injection molding) and five denture base resin materials-two milled CAD-CAM materials (AvaDent and IvoBase), two 3D-printed materials (NextDent and HARZ Labs), and one injection-molded material (iFlextm). Based on the denture base type, the study divided them into five groups (each with n = 10). An evaluation of duplication accuracy was conducted on the fitting surface of each complete denture base (CDB) using two assessment methods. The first method was a two-dimensional evaluation, which entailed linear measurements of the distances (A-B, A-C, and B-C) between reference points on both the scanned reference mandibular denture and the duplicated dentures. Additionally, a three-dimensional superimposition technique was employed, involving the overlay of the STL files of the dentures onto the reference denture's STL file. The collected data underwent statistical analysis using a one-way analysis of variance and Tukey's pairwise post hoc tests.

RESULTS

Both evaluation techniques showed significant differences in fitting surface accuracy between the tested CDBs (p ˂ 0.001), as indicated by one-way ANOVA. In addition, the milled CDBs (AvaDent and IvoBase) had significantly higher fitting surface accuracy than the other groups (p ˂ 0.001) and were followed by 3D-printed CDBs (NextDent and HARZ Labs), while the injection-molded (iFlextm) CDBs had the lowest accuracy (p ˂ 0.001).

CONCLUSIONS

The duplication technique of complete dentures using a CAD-CAM milling system produced superior fitting surface accuracy compared to the 3D-printing and injection-molded techniques.

Assessing the effect of Artemisia sieberi extracts on surface roughness and candida growth of digitally processed denture acrylic materials

BACKGROUND

Denture stomatitis, frequently encountered, is generally addressed symptomatically, with limited exploration of preventive approaches involving antifungal medicinal plants.

OBJECTIVE

This study assessed the impact of Artemisia sieberi extracts on the candida growth of conventional and digitally processed acrylic materials.

METHOD

Thirty acrylic resin discs (3 mm thickness × 10 mm diameter) were prepared by conventional or CAD/CAM technology (milling and 3D printing). The resin discs were exposed to simulated brushing, thermocycling, and immersion in Artemisia sieberi extract for 8 hours. The surface roughness of the discs was assessed at baseline and after immersion in Artemisia sieberi extract. Candida growth was quantified through colony-forming units (CFU/mL). Data was analyzed using SPSS v.22 (α⩽ 0.05).

RESULTS

Irrespective of the material type, the post-immersion surface roughness was significantly higher compared to pre-immersion values (p< 0.05). Candida growth was significantly higher in conventional acrylic materials than digitally fabricated acrylics (p< 0.05). At × 3, Ra and CFU were found to be moderately positive and non-significantly correlated (R= 0.664, p= 0.149). At × 4, Ra and CFU were found to be weak positive and non-significantly correlated (R= 0.344, p= 0.503).

CONCLUSION

Artemisia sieberi extracts had a notable impact on digitally fabricated denture acrylics, reducing candida albicans growth compared to conventional heat-cured acrylic. This suggests a potential role for these extracts in improving denture hygiene and preventing denture stomatitis, particularly in the context of digitally fabricated dentures.

Digital duplication of maxillary complete denture: A dental technique

OBJECTIVE

This technique aims to construct a virtual, well-adapted maxillary denture from an existing, ill-fitting denture in completely edentulous patients.

CLINICAL CONSIDERATIONS

A functional impression is made using the loose maxillary denture, and a cone beam computed tomography (CBCT) of the entire old denture is carried out. The obtained digital imaging and communication in medicine (DICOM) file was segmented using an image computing platform software (3D slicer). The resultant Standard Tessellation Language (STL) file was 3D printed in porcelain white-like resin, then colored and characterized.

CONCLUSIONS

The technique introduces a high-quality digital denture replicate with good retention, that can replace the traditional duplication technique. It can also be used as a relining method for old dentures. This proposed digital technique reduces the number of clinical appointments while also providing a digital library for future denture manufacture.

CLINICAL SIGNIFICANCE

The proposed technique offers a high-quality digital denture replicate that can replace the traditional duplication technique. This digital technique also reduces the number of clinical appointments required for denture duplication.

Effect of layer thickness, build angle, and viscosity on the mechanical properties and manufacturing trueness of denture base resin for digital light processing

OBJECTIVES

To investigate effects of layer thickness, build angle, and viscosity on the mechanical properties and trueness of denture base resins used for digital light processing (DLP).

METHODS

Two denture base resins for DLP in different viscosity (high and low) were tested by using two manufacturing parameters:1) layer thickness (LT) (50- or 100-μm) and 2) build angle (BA) (0-, 45-, and 90-degree). disk- and bar-shaped specimens were used to evaluate hardness and flexural strength, respectively. Denture base specimens were used to examine trueness, and the deviation was calculated as the root mean square. Three-way analysis of variance (ANOVA) was conducted to determine the interaction among the three factors (viscosity, LT, and BA). Statistical significance was set at P < .05.

RESULTS

Effects of LT and BA on hardness differed according to viscosity, with significant interactions among three factors (P=.027). Regardless of LT or BA, the low-viscosity group had higher hardness than the high-viscosity group (P<.001). In terms of flexural strength, no significant interaction was detected between the factors (P=.212), however, the effects of LT and BA were significant (P=.003 and P<.001, respectively). Regarding trueness, a significant interaction was observed between viscosity and BA (P=.001). Low-viscosity group had higher trueness than high-viscosity group when the 45- and 90-degree BA were applied (P<.001).

CONCLUSIONS

LT and BA significantly affected the mechanical properties and trueness of the 3DP denture base, depending on the viscosity. For hardness and trueness, using low-viscosity resin and manufacturing with 50-μm LT and 45-degree BA are recommended.

CLINICAL SIGNIFICANCE

Resin viscosity affects the influence of LT and BA on the hardness, flexural strength, and trueness of DLP-generated denture bases. A 50-μm LT and 45-degree BA can be used with a low-viscosity resin to fabricate denture bases with higher hardness and trueness.

Repair Bond Strength of Conventionally and Digitally Fabricated Denture Base Resins to Auto-Polymerized Acrylic Resin: Surface Treatment Effects In Vitro

Denture base fracture is one of the most annoying problems for both prosthodontists and patients. Denture repair is considered to be an appropriate solution rather than fabricating a new denture. Digital denture fabrication is widely spreading nowadays. However, the repair strength of CAD-CAM milled and 3D-printed resins is lacking. This study aimed to evaluate the effect of surface treatment on the shear bond strength (SBS) of conventionally and digitally fabricated denture base resins. One l heat-polymerized (Major base20), two milled (IvoCad, AvaDent), and three 3D-printed (ASIGA, NextDent, FormLabs) denture base resins were used to fabricate 10 × 10 × 3.3 acrylic specimens (N = 180, 30/resin, n = 10). Specimens were divided into three groups according to surface treatment; no treatment (control), monomer application (MMA), or sandblasting (SB) surface treatments were performed. Repair resin was bonded to the resin surface followed by thermocycling (5000 cycles). SBS was tested using a universal testing machine where a load was applied at the resin interface (0.5 mm/min). Data were collected and analyzed using ANOVA and a post hoc Tukey test (α = 0.05). SEM was used for failure type and topography of fractured surfaces analysis. The heat-polymerized and CAD-CAM milled groups showed close SBS values without significance (p > 0.05), while the 3D-printed resin groups showed a significant decrease in SBS (p < 0.0001). SBS increased significantly with monomer application (p < 0.0001) except for the ASIGA and NextDent groups, which showed no significant difference compared to the control groups (p > 0.05). All materials with SB surface treatment showed a significant increase in SBS when compared with the controls and MMA application (p < 0.0001). Adhesive failure type was observed in the control groups, which dramatically changed to cohesive or mixed in groups with surface treatment. The SBS of 3D-printed resin was decreased when compared with the conventional and CAD-CAM milled resin. Regardless of the material type, SB and MMA applications increased the SBS of the repaired resin and SB showed high performance.