In Vitro Analysis of the Fracture Resistance of CAD/CAM Denture Base Resins

Clinical use of duplicate complete dentures: A narrative review

Most reports on duplicate dentures are introduction to fabrication methods or clinical case reports. Only a few studies have verified their clinical effectiveness; hence, evidence to construct useful clinical guidelines for duplicate denture use is lacking. This review aimed to comprehensively investigate reports on duplicate dentures to accumulate evidences that will contribute to the formulation of clinical practice guidelines. Duplicate dentures are effectively used for impression making and bite registration when fabricating new dentures, thereby reducing the number of clinic visits and treatment time. Duplicate denture can also be used as temporary or new dentures. Older people in whom various adaptive abilities have declined, may find it difficult to adjust to new dentures and experience stress, even if the shape is appropriate. Duplicate dentures, which reproduces the shape of old dentures that they are used to, have the advantage of being more familiar to older people and less stressful. When manufacturing duplicate dentures, digital methods such as milling and three-dimensional printing are superior to conventional methods regarding working time and cost. A notable advantage of the digital method is that the denture shape can be saved as digital data, and the denture can be easily duplicated if lost.

Comparison of the flexural strength of printed and milled denture base materials

BACKGROUND

To evaluate the flexural strength of digitally milled and printed denture base materials.

METHODS

The materials tested were Lucitone 199 denture base disc (Dentsply Sirona), AvaDent denture base puck (AvaDent), KeyMill denture base disc (Keystone), Lucitone digital print denture base resin (Dentsply Sirona), Formlab denture base resin (Formlabs), and Dentca base resin II (Dentca). Sixty bar-shaped specimens of each material were prepared for flexural strength testing and were divided into five groups: control, thermocycled, fatigue cycled, and repair using two different materials. The flexural strength and modulus were tested using a 3-point bend test performed on an Instron Universal Testing Machine with a 1kN load cell. The specimens were centered under a loading apparatus with a perpendicular alignment. The loading rate was a crosshead speed of 0.5 mm/min. Each specimen was loaded with a force until failure occurred. A one-way ANOVA test was used to analyze the data, followed by Tukey's HSD test (α = 0.05).

RESULTS

The milled materials exhibited higher flexural strength than the printed materials. Thermocycling and fatigue reduce the flexural strengths of printed and milled materials. The repaired groups exhibited flexural strengths of 32.80% and 30.67% of the original flexural strengths of printed and milled materials, respectively. Nevertheless, the type of repair material affected the flexural strength of the printed materials; the composite resin exhibited higher flexural strength values than the acrylic resin.

CONCLUSIONS

The milled denture base materials showed higher flexural strength than the printed ones.

Digital versus conventional complete dentures: A randomized, controlled, double-blinded crossover trial

STATEMENT OF PROBLEM

The Baltic Denture System provides a digital way to fabricate complete dentures in 2 visits. Conventional dentures using injection or compression molding require additional visits and complex laboratory procedures. However, how the fabrication method affects clinical outcomes is unclear.

PURPOSE

The purpose of this clinical, randomized, controlled, double-blinded crossover trial was to evaluate the impact of the fabrication method (digital versus conventional production) of complete dentures on clinical outcomes.

MATERIAL AND METHODS

Sixteen participants received 2 pairs of new complete dentures, produced in a digital and a conventional workflow. Each complete denture was worn for an observation period of 3 months. The order of the dentures was randomized. The primary outcome was the clinical assessment of the dentures by a blinded examiner, including peripheral extension, cutout for buccal and labial frenula, denture extension, and denture thickness. Denture esthetics were evaluated by the midline, position of anterior teeth, buccal corridor, and smile arc, and occlusal relationships were evaluated by the vertical dimension, sagittal relation, the Camper plane, and occlusion. In addition, the retention of maxillary and mandibular dentures and phonetics was evaluated. Differences between the prostheses were statistically analyzed with the McNemar test (α=.05).

RESULTS

The borders of the digital dentures were significantly more often overextended at the time of insertion (P=.021), reducing the retention of the digital dentures, especially the maxillary dentures (P=.016). The borders of the dentures could be corrected so that after 2 weeks and 3 months, no significant differences could be seen between digital dentures and conventional dentures.

CONCLUSIONS

The fabrication method has a significant influence only on the dimension of the denture border. It was significantly more often overextended in digital dentures and impaired retention, especially of the maxillary dentures, at the time of insertion. As this parameter is correctable, no significant clinical differences could be observed over the observation time of 3 months between digital dentures and conventional dentures.

Impact of Artificial Aging on the Physical and Mechanical Characteristics of Denture Base Materials Fabricated via 3D Printing

Three-dimensional (3D) printing is becoming more prevalent in the dental sector due to its potential to save time for dental practitioners, streamline fabrication processes, enhance precision and consistency in fabricating prosthetic models, and offer cost-effective solutions. However, the effect of aging in artificial saliva of this type of material has not been explored. To assess the physical and mechanical properties of the two types of 3D-printed materials before and after being subjected to artificial saliva, a total of 219 acrylic resin specimens were produced. These specimens were made with two types of 3D-printed materials, namely, NextDent (ND) and Formlabs (FLs), and a Schottlander heat-cured (HC) resin material that was used as a control. Water sorption and solubility specimens (n = 5) were tested after three months of storage in artificial saliva. Moreover, the Vickers hardness, Martens hardness, flexural strength/modulus, and impact strength were evaluated both under dry conditions and after three months of storage in artificial saliva. The degree of conversion (DC), elemental analysis, and filler content were also investigated. The ANOVA showed that 3D-printed resins had significantly greater sorption than the control group (p < 0.05). However, the flexural strength values of the 3D-printed materials were significantly greater (p < 0.05) than those of the heat-cured material. The DC of the 3D-printed resins was lower than that of the control group, but the difference was not significant (p > 0.05). The 3D-printed materials contained significantly more filler than the control (p < 0.05). Moreover, the artificial saliva had a significant effect on the Vickers hardness for all tested groups and on the Martens hardness for the control group only (p < 0.05). Compared with conventional heat-cured materials, 3D-printed denture base materials demonstrated relatively poorer performance in terms of sorption, solubility, and DC but exhibited either comparable or superior mechanical properties. The aging process also influenced the Vickers and Martens' hardness. The strength of the 3D-printed materials was in compliance with ISO recommendations, and the materials could be used alongside conventional heat-cured materials.

The Influence of Contemporary Denture Base Fabrication Methods on Residual Monomer Content, Flexural Strength and Microhardness

(1) Background: Digital technologies are available for denture base fabrication, but there is a lack of scientific data on the mechanical and chemical properties of the materials produced in this way. Therefore, the aim of this study was to investigate the residual monomer content, flexural strength and microhardness of denture base materials as well as correlations between investigated parameters. (2) Methods: Seven denture base materials were used: one conventional heat cured polymethyl methacrylate, one polyamide, three subtractive manufactured materials and two additive manufactured materials. High-performance liquid chromatography was used to determine residual monomer content and the test was carried out in accordance with the specification ISO No. 20795-1:2013. Flexural strength was also determined according to the specification ISO No. 20795-1:2013. The Vickers method was used to investigate microhardness. A one-way ANOVA with a Bonferroni post-hoc test was used for the statistical analysis. The Pearson correlation test was used for the correlation analysis. (3) Results: There was a statistically significant difference between the values of residual monomer content of the different denture base materials (p < 0.05). Anaxdent pink blank showed the highest value of 3.2% mass fraction, while Polident pink CAD-CAM showed the lowest value of 0.05% mass fraction. The difference between the flexural strength values of the different denture base materials was statistically significant (p < 0.05), with values ranging from 62.57 megapascals (MPa) to 103.33 MPa. The difference between the microhardness values for the different denture base materials was statistically significant (p < 0.05), and the values obtained ranged from 10.61 to 22.86 Vickers hardness number (VHN). A correlation was found between some results for the material properties investigated (p < 0.05). (4) Conclusions: The selection of contemporary digital denture base manufacturing techniques may affect residual monomer content, flexural strength and microhardness but is not the only criterion for achieving favourable properties.

Fracture toughness, work of fracture, flexural strength and elastic modulus of 3D-printed denture base resins in two measurement environments after artificial aging

OBJECTIVES

To investigate the fracture toughness (KIC), work of fracture (WOF), flexural strength (FS) and elastic modulus (E) of four additively manufactured denture base resins in two different measurement environments after artificial aging.

METHODS

Rectangular specimens in two different dimensions (n = 480) were 3D-printed with four denture base resins: Denture 3D+ (DEN; NextDent), Fotodent Denture (FOT; Dreve ProDiMed), Freeprint Denture (FRE; Detax), V-Print dentbase (VPR; VOCO)). KIC, WOF, FS and E were measured after (1) water-storage (37 °C; KIC = 7 d; FS = 50 h); (2) water-storage + hydrothermal-aging (20 min, 0.2 MPa, 134 °C); (3) water storage + thermocycling (10,000 cycles, 5/55 °C) in two measurement environments (i) air-23 °C and (ii) water-37 °C. For FS, fracture types were classified, and relative frequencies determined. Univariate ANOVA, Kruskal-Wallis, Mann-Whitney U, and Spearman's correlation were calculated (p < 0.05, SPSS V.27.0). Weibull modulus (m) was calculated using the maximum likelihood estimation method.

RESULTS

DEN showed the highest KIC (5/6 groups), WOF and highest corresponding m (1/6 groups), while FRE presented the highest FS (2/6 groups) and E values. Hydrothermal-aging and thermocycling reduced KIC and WOF, FS and E, and the number of FS fracture pieces. For 6/8 groups, hydrothermal aging resulted in lower FS than thermocycling. Measurement in air-23 °C led to higher FS for 7/12 groups and a more brittle fracture behavior. A positive correlation between KIC and FS was observed.

SIGNIFICANCE

With measurements in air-23 °C resulting in higher FS than reported in water-37 °C, the measurement environment should be adapted to the clinical situation to allow valid predictions on the mechanical behavior of denture base resins when in situ.

Tensile Bond Strength between Different Denture Base Materials and Soft Denture Liners

(1) Background: Various materials are available for CAD-CAM denture base fabrication, for both additive and subtractive manufacturing. However, little has been reported on bond strength to soft denture liners. Therefore, the aim of this study was to investigate tensile bond strength, comparing between different denture base materials and soft denture liners. (2) Methods: Seven different materials were used for denture base fabrication: one heat-polymerized polymethyl methacrylate, three materials for subtractive manufacturing, two materials for additive manufacturing and one polyamide. Two materials were used for soft denture lining: one silicone-based and one acrylate-based. The study was conducted according to the specification ISO No. 10139-2:2016, and the type of failure was determined. The Kruskal-Wallis test with Dunn's post hoc test was used to analyse the values of tensile bond strength, and Fisher's exact test was used to analyse the type of failure. p Values < 0.05 were considered statistically significant. (3) Results: The tensile bond strength values were not statistically significantly different combining all the materials used for denture base fabrication with the acrylate-based soft denture liner (p > 0.05), and the average values ranged between 0.19 and 0.25 Mpa. The tensile bond strength values of the different denture base materials and silicone-based denture liner were statistically significantly different (p < 0.05), and the average values ranged between 1.49 and 3.07 Mpa. The type of failure was predominantly adhesive between polyamide and both additive-manufactured denture base materials in combination with the acrylate-based soft liner (p < 0.05). (4) Conclusions: The use of digital technologies in denture base fabrication can have an influence on different tensile bond strength values for soft denture liners, with different types of failure when compared with heat-cured PMMA. Similar tensile bond strength values were found between the acrylate-based soft denture liner and denture base materials. Significant differences in tensile bond strength values were found between the silicone-based soft denture liner and denture base materials, where the additive-manufactured and polyamide denture base materials showed lower values than heat-cured PMMA and subtractive-manufactured denture base materials.

Experimental Study on Mechanical Properties of Different Resins Used in Oral Environments

Background and Objectives: Acrylic resins remain the materials of choice for removable prosthesis due to their indisputable qualities. The continuous evolution in the field of dental materials offers practitioners today a multitude of therapeutic options. With the development of digital technologies, including both subtractive and additive methods, workflow has been considerably reduced and the precision of prosthetic devices has increased. The superiority of prostheses made by digital methods compared to conventional prostheses is much debated in the literature. Our study's objective was to compare the mechanical and surface properties of three types of resins used in conventional, subtractive, and additive technologies and to determine the optimal material and the most appropriate technology to obtain removable dentures with the highest mechanical longevity over time. Materials and Methods: For the mechanical tests, 90 samples were fabricated using the conventional method (heat curing), CAD/CAM milling, and 3D printing technology. The samples were analyzed for hardness, roughness, and tensile tests, and the data were statistically compared using Stata 16.1 software (StataCorp, College Station, TX, USA). A finite element method was used to show the behavior of the experimental samples in terms of the crack shape and its direction of propagation. For this assessment the materials had to be designed inside simulation software that has similar mechanical properties to those used for obtaining specimens for tensile tests. Results: The results of this study suggested that CAD/CAM milled samples showed superior surface characteristics and mechanical properties, comparable with conventional heat-cured resin samples. The propagation direction predicted by the finite element analysis (FEA) software was similar to that observed in a real-life specimen subjected to a tensile test. Conclusions: Removable dentures made from heat-cured resins remain a clinically acceptable option due to their surface quality, mechanical properties, and affordability. Three-dimensional printing technology can be successfully used as a provisional or emergency therapeutic solution. CAD/CAM milled resins exhibit the best mechanical properties with great surface finishes compared to the other two processing methods.

Evaluation of physicomechanical properties of milled versus 3D-printed denture base resins: A comparative in vitro study

STATEMENT OF PROBLEM

Studies comparing the physicomechanical characteristics of denture base resins manufactured by computer-aided design and computer-aided manufacturing (CAD-CAM) milling and 3-dimensional (3D) printing are sparse, resulting in challenges when choosing a fabrication method for complete dentures.

PURPOSE

The purpose of this in vitro study was to evaluate and compare the impact strength, flexural strength, and the surface roughness of denture base resins manufactured by CAD-CAM milling and 3D printing before and after thermocycling and polishing.

MATERIAL AND METHODS

Evaluation of the physicomechanical properties (n=35) was completed before and after 500 thermocycles. Impact strength (n=14) was measured with a Charpy impact tester and flexural strength (n=14) with the 3-point bend test. Surface roughness (Ra) was evaluated (n=7) with a profilometer before and after thermocycling and polishing and by viewing the surface topography before and after polishing using a scanning electron microscope at ×2000. The Mann-Whitney U test and Wilcoxon sign rank test were used for statistical analysis (α=.05).

RESULTS

Milled specimens showed statistically significantly higher impact strength before thermocycling and statistically significantly higher flexural strength before and after thermocycling (P=.004) compared with 3D-printed specimens. The Ra values for the milled group were significantly lower than for the 3D-printed group both before and after thermocycling (P=.006) and after polishing (P=.027). Thermocycling resulted in a statistically significant difference in flexural strength (P=.018) in both groups and in surface roughness in the milled group (P=.048); but no significant effect was found on impact strength (P>.05). Ra values for the 3D-printed group decreased after polishing (P=.048).

CONCLUSIONS

Milled specimens had higher flexural and impact strength and lower surface roughness values than 3D-printed specimens. Polishing significantly reduced the surface roughness in 3D-printed specimens but had no significant effect on milled specimens.

A Comparison of the Surface and Mechanical Properties of 3D Printable Denture-Base Resin Material and Conventional Polymethylmethacrylate (PMMA)

PURPOSE

To study the surface and mechanical properties of 3D printed denture-base resin materials and compare them with conventional heat-cured polymethylmethacrylate (PMMA).

MATERIALS AND METHODS

Three brands of 3D printed denture-base resin materials and one conventional heat-cured PMMA were tested in this study: NextDent 3D printed resin, Dentona 3D printed resin, ASIGA 3D printed resin, and Meliodent conventional PMMA. Sixty specimens (25 × 25 × 3 mm) were fabricated (n=15 per group) to perform the following tests: wettability, surface roughness, and microhardness. One hundred twenty specimens (65 × 10 × 3 mm) were fabricated (n=30 per group) and stored in distilled water at (37 ±1°C) for 7 days. Specimens (N = 15) in each group were subjected to the three-point bending test and impact strength test, employing the Charpy configuration on un-notched specimens. The morphology of the fractured specimens was studied under scanning electron microscope (SEM). Statistical analysis was performed using one-way ANOVA and Tukey-pairwise multiple comparisons with 95% confidence interval. P-values of ≤0.05 were considered significant.

RESULTS

The conventional heat-cured specimens demonstrated the highest means of surface roughness (0.23 ± 0.07 μm), Vickers hardness number (18.11 ±0.65) and flexural strength (92.44 ±7.91 MPa), and the lowest mean of contact angle (66.71° ±3.38°). ASIGA group showed the highest mean of contact angle (73.44° ±2.74°) and the lowest mean of surface roughness (0.19 ±0.03 μm). The highest mean of impact strength was recorded in the Dentona group (17.98 ±1.76 kg/m² ). NextDent specimens showed the lowest means of Vickers hardness number (16.20 ±0.93), flexural strength (74.89 ±8.44 MPa), impact strength (15.20 ±0.69 kg/m² ), and recorded the highest mean of bending modulus (2,115.80 ±178.95 MPa).

CONCLUSIONS

3D printed resin exhibited noticeable differences in surface and mechanical properties between different brands and with conventional heat-polymerized PMMA.

In Vitro Analysis of Shear Stress: CAD Milled vs Printed Denture Base Resins with Bonded Denture Tooth

PURPOSE

As the fabrication of computer-aided design (CAD) milled and 3D printed denture base resins with bonded denture teeth increase in popularity, there is a need for research comparing the shear bond stress of milled and printed denture base resins with bonded denture teeth to that of a conventional heat processed denture base.

MATERIALS AND METHODS

Denture base resin specimens (n = 9) were fabricated according to manufacturers' instructions using a novel test design. Two milled (Ivobase CAD PMMA, Ivoclar Vivadent and Polident PMMA, Polident Dental) and two 3D printed (Denture Base LP Resin, Formlabs and Lucitone Digital Print, Dentsply Sirona) materials were used. Conventional heat processed polymethylmethacrylate was used as the control (Lucitone 199, Dentsply Sirona). Denture teeth (VITA Vitapan XL T44, #8, VITA Zahnfabrik) were bonded to their respective bases using denture tooth bonding agent (Ivobase CAD bonding system, Ivoclar). Specimens were aged in water for 600 hours at 37°C and loaded until failure in a Universal testing machine. Shear bond stress was calculated. All specimens were evaluated for mode of failure and select specimens under scanning electron microscope and vertical scanning interferometry. Data were analyzed with one-way ANOVA followed by Tukey test (IBM SPSS) and fracture analysis performed.

RESULTS

Shear stress was highest for the heat processed control (mean = 180 N ±26.76) and Polident test groups (mean = 180 N ± 34.90). Milled specimens were not significantly different from the control (p = 0.076 for IvoBase CAD and 1.00 for Polident), while the printed groups were significantly different from the control (p = 0.012 for Formlabs Denture Base Resin and p = 0.00 for Carbon Lucitone Digital Print). Milled denture base resins performed similarly to heat processed denture base resin and better than 3D printed denture bases.

CONCLUSION

For complete denture wearers, all resin materials used in this study may be clinically acceptable, as the sheer stress for all groups was higher than the reported maximum biting force of complete denture patients. However, for implant retained prostheses, the incorporation of additional retentive features should be considered when bonding denture teeth to printed bases. More research is needed to evaluate methods to increase the bond strength of denture teeth to printed denture base resins.

Physical, mechanical and anti-biofilm formation properties of CAD-CAM milled or 3D printed denture base resins: In Vitro analysis

PURPOSE

To investigate surface characteristics (roughness and contact angle), anti-biofilm formation, and mechanical properties (mini-flexural strength) of computer-aided design and computer-aided manufacturing (CAD-CAM) PMMA polymer, and three-dimensional (3D) printed resin for denture base fabrication compared with conventional heat polymerized denture base resins.

MATERIALS AND METHODS

A total of 60 discs and 40 rectangular specimens were fabricated from one CAD-CAM (AvaDent), one 3D printed (Cosmos Denture), and two conventional heat polymerized (Lucitone 199 and VipiWave) materials for denture base fabrication. Roughness was determined by Ra value; the contact angle was measured by the sessile drop method; the biofilm formation inhibition behavior was analyzed through C. albicans adhesion, while mini-flexural strength test was done using a three-point bending test. The data were analyzed using descriptive and analytical statistics (α = 0.05).

RESULTS

The CAD-CAM PMMA group showed the lowest C. albicans adhesion (log CFU/mL: 3.74 ±0.57) and highest mini-flexural strength mean (114.96 ±16.23 MPa). 3D printed specimens presented the highest surface roughness (Ra: 0.317 ±0.151 μm) and lowest mini-flexural strength values (57.23 ±9.07 MPa). However, there was no statistical difference between CAD-CAM PMMA and conventional groups for roughness, contact angle, and mini-flexural strength.

CONCLUSIONS

CAD-CAM milled materials present surface and mechanical properties similar to conventional resins and show improved behavior preventing C. albicans adhesion. Nevertheless, 3D printed resins present decreased mini-flexural strength. This article is protected by copyright. All rights reserved.

Additive Manufacturing for Complete Denture Fabrication: A Narrative Review

PURPOSE

To evaluate and compare the benefits and limitations of additive manufacturing for complete denture fabrication.

METHODS

A PubMed and Google Scholar search for topics pertaining to additive manufacturing for complete dentures was performed. The resulting articles were then divided into topics to allow a narrative review.

DISCUSSION

Determining how printing compares with conventional and milled dentures is critical for the widespread adoption of this fabrication technique. Physical properties, denture tooth bond strength, denture base adaptation and soft-liner bond strength are discussed to establish how printing compares.

CONCLUSIONS

Printing offers many advantages over milled and conventionally processed dentures; however, many questions need to be answered by research. The advantages include reduced cost of most printers compared to milling machines, less material waste, ability to print multiple dentures simultaneously, and complex designs can be fabricated that otherwise could not be milled. Current research has shown flexural strength, fracture toughness, color stability, and denture base adaptation are reduced for printed dentures when compared with milled dentures. Print orientation has been shown to influence accuracy, strength, surface roughness and C. albicans adherence which is not seen with conventional or milled denture materials. These factors do not represent a criticism of printing but rather indicate the need for more research with this new and promising denture fabrication technique. Since printing offers numerous benefits to complete denture fabrication it is likely to have a more significant role in complete denture fabrication in years to come as knowledge increases and materials/techniques continue to advance.

Effective utilization of digital technology in complete denture fabrication

Although digital technology is commonly used in various forms of dental treatment, its application to fabrication of removable dentures is still associated with limitations or challenges, such as the recording of occlusal vertical dimensions and determination of the occlusal plane. Here, a simple and inexpensive technique for fabrication of removable complete dentures, partly aided by digital technology, is proposed.

Flexural strength of CAD/CAM denture base materials: Systematic review and meta-analysis of in-vitro studies

Introduction:

Digital complete dentures fabrication techniques are expanding. This study aimed to review flexural strength (FS) of milled and 3D-printed denture base materials to answer the study question: is FS of computer-aided designing/computer-aided manufacturing (CAD/CAM) denture base comparable to conventional heat-polymerized materials?

Materials and Methods:

Search was done within different databases for articles published between January 2010 and June 2021 using specific keywords. Articles of in-vitro studies in English language with methods following International Standards Organization standardization/ADA specifications for flexural testing of conventional and CAD/CAM (milled or printed) polymethyl methacrylate (PMMA) materials were included.

Results:

Out of the 61 studies, 9 were processed for data extraction and only 7 underwent meta-analysis. Two, six, and one study showed high, moderate, and low risk of bias, respectively. Random-effects model was used for analysis and resulted in the average FS of 120.61 MPa [95% confidence interval (CI): 109.81−131.41] and 92.16 MPa (CI: 75.12−109.19) for CAD/CAM milled and heat-polymerized PMMA, respectively.

Conclusion:

Subtractive CAD/CAM technique of denture fabrication showed satisfactory FS values, whereas additive CAD/CAM method was comparable to conventional heat-polymerized technique with lower value, requiring further investigations and improvement. The clinical use of milled denture bases is an acceptable substitution to heat-polymerized PMMA, making the denture fabrication an easier and faster process.

Flexural strength and impact strength of heat-cured acrylic and 3D printed denture base resins- A comparative in vitro study

Objective

The present study aimed to evaluate and compare the flexural strength and impact strength of heat-cured acrylic/Polymethyl methacrylate (PMMA) denture base resin and 3D printed denture base resin.

Methods

60 rectangular specimens were fabricated from conventional heat-cured acrylic and 3D-printed denture base resins. 15 specimens each of heat-cured acrylic and 3D printed denture base resin were tested for flexural strength and impact strength. The flexural strength was assessed using three point bend test while impact strength was assessed by Izod impact test.

Results

The mean flexural strength of heat-cured acrylic resin was 92.01 ± 12.14 MPa and 3D printed denture base resin was 69.78 ± 7.54 MPa. The mean impact strength of heat-cured acrylic resin was 1.67 ± 0.79 kJ/m² and 3D printed denture base resin was 1.15 ± 0.40 kJ/m².The differences in mean impact and flexural strength between heat-cured acrylic and 3D printed denture base resins were statistically significant.

Conclusion

Heat-cured acrylic denture base resin (DPI heat-cure) had greater flexural and impact strength than 3D printed denture base resin (Next Dent denture 3D+).

CAD-CAM complete removable dental prostheses: A double-blind, randomized, crossover clinical trial evaluating milled and 3D-printed dentures

OBJECTIVE

This double-blind, randomized, crossover, clinical trial aimed to evaluate and compare the differences between milled and 3D-printed complete removable dental prostheses (CRDPs).

METHODS

Fifteen edentulous patients (men: n = 10, women: n = 5; age: 66.7 ± 8.0 years) rehabilitated with conventional CRDPs were recruited for this trial. Participants were randomized to first receiving either the milled or 3D-printed CAD-CAM manufactured CRDPs and then after 6-weeks cross over to the other set. Both, clinicians and participants were blinded to the group allocation. Outcomes included patient's denture satisfaction (PDS), oral-health related quality of life (OHIP-EDENT), willingness-to-pay analysis, final choice (FC) of CRDPs, clinician's denture quality evaluation (CDQE), chewing efficiency (CE), maximum-voluntary-bite-force (MBF), and prosthodontic maintenance needs. The outcomes were measured at baseline (with old CRDPs), at 1 and 6 weeks after new CRDP insertion; following crossover with the second set of CRDPs, an identical protocol was followed. Generalized linear regression for repeated measures was used for statistical analysis with α=0.05.

RESULTS

All participants completed the trial. 3D-printed CRDPs required more maintenance visits, adjustment time (p = 0.0003), and adjustment costs (p = 0.021). Patients were willing-to-pay an average of 606.67 Swiss Francs more than the actual cost for the milled CRDPs. There were no differences in the PDS, OHIP, FC, CDQE, CE, and MBF between the two CRDPs groups.

CONCLUSIONS

The findings of this double-blind randomized crossover clinical trial confirm that both milled and 3D-printed CRDPs are valid treatment modalities for edentulous patients, with the latter performing inferiorly with regard to the time and costs involved with the prosthodontic aftercare, as well as the patients' willingness-to-pay.

CLINICAL RELEVANCE

The findings of this trial provide evidence to help the clinician in choosing the appropriate CAD-CAM manufacturing process for fabricating the CRDPs.

3D-Printed vs. Heat-Polymerizing and Autopolymerizing Denture Base Acrylic Resins

The aim of this work was to investigate the effect of two post-curing methods on the mechanical properties of a 3D-printed denture base material. Additionally, to compare the mechanical properties of that 3D-printed material with those of conventional autopolymerizing and a heat-cured denture base material. A resin for 3D-printing denture base (Imprimo^®), a heat-polymerizing acrylic resin (Paladon^® 65), and an autopolymerizing acrylic resin (Palapress^®) were investigated. Flexural strength, elastic modulus, fracture toughness, work of fracture, water sorption, and water solubility were evaluated. The 3D-printed test specimens were post-cured using two different units (Imprimo Cure^® and Form Cure^®). The tests were carried out after both dry and 30 days water storage. Data were collected and statistically analyzed. Resin type had a significant effect on the flexural strength, elastic modulus, fracture toughness, and work of fracture (p < 0.001). The flexural strength and elastic modulus for the heat-cured polymer were significantly the highest among all investigated groups regardless of the storage condition (p < 0.001). The fracture toughness and work of fracture of the 3D-printed material were significantly the lowest (p < 0.001). The heat-cured polymer had the lowest significant water solubility (p < 0.001). The post-curing method had an impact on the flexural strength of the investigated 3D-printed denture base material. The flexural strength, elastic modulus, fracture toughness, work of fracture of the 3D-printed material were inferior to those of the heat-cured one. Increased post-curing temperature may enhance the flexural properties of resin monomers used for 3D-printing dental appliances.

CAD-CAM removable complete dentures: A systematic review and meta-analysis of trueness of fit, biocompatibility, mechanical properties, surface characteristics, color stability, time-cost analysis, clinical and patient-reported outcomes

OBJECTIVES

This review compared Computer-aided designand Computer-aided manufactured (CAD-CAM) and conventionally constructed removable complete dentures (CDs).

DATA

Seventy-three studies reporting on CAD-CAM (milled/3D-printed) CDs were included in this review. The most recent literature search was performed on 15/03/2021.

SOURCES

Two investigators searched electronic databases [PubMed (MEDLINE), Embase, CENTRAL], online search engines (Google) and research portals. Hand searches were performed to identify literature not available online.

STUDY SELECTION

Studies on CAD-CAM CDs were included if they reported on trueness of fit, biocompatibility, mechanical, surface, chemical, color , microbiological properties, time-cost analysis, and clinical outcomes. Inter-investigator reliability was assessed using kappa scores. Meta-analyses were performed on the extracted data .

RESULTS

The kappa score ranged between 0.897-1.000. Meta-analyses revealed that 3D-printed CDs were more true than conventional CDs (p = 0.039). Milled CDs had a higher flexural-strength than conventional and 3D-printed CDs (p < 0.0001). Milled CDs had a higher flexural-modulus than 3D-printed CDs (p < 0.0001). Milled CDs had a higher yield-strength than injection-molded (p = 0.004), and 3D-printed CDs (p = 0.001). Milled CDs had superior toughness (p < 0.0001) and surface roughness characteristics (p < 0.0001) than other CDs . Rapidly-prototyped CDs displayed poor color-stability compared to other CDs (p = 0.029). CAD-CAM CDs d displayed better retention than conventional CDs (p = 0.015). Conventional CDs had a higher strain at yield point than milled CDs (p < 0.0001), and had superior esthetics than 3D-printed (p < 0.0001). Fabrication of CAD-CAM CDs required less chairside time (p = 0.037) and lower overall costs (p < 0.0001) than conventional CDs.

CONCLUSIONS

This systematic review concludes that CAD-CAM CDs offer a number of improved mechanical/surface properties and are not inferior when compared to conventional CDs.

CLINICAL SIGNIFICANCE

CAD-CAM CDs should be considered for completely edentulous patients whenever possible, since this technique offers numerous advantages including better retention, mechanical and surface properties but most importantly preserves a digital record. This can be a great advantage for older adults with limited access to dental care.

Strength and Surface Properties of a 3D-Printed Denture Base Polymer

PURPOSE

This in vitro study evaluated the flexural strength, impact strength, hardness, and surface roughness of 3D-printed denture base resin subjected to thermal cycling treatment.

MATERIALS AND METHODS

According to ISO 20795-1:2013 standards, 120 acrylic resin specimens (40/flexural strength test, 40/impact strength, and 40/surface roughness and hardness test, n = 10) were fabricated and distributed into two groups: heat-polymerized; (Major.Base.20) as control and 3D-printed (NextDent) as experimental group. Half of the specimens of each group were subjected to 10,000 thermal cycles of 5 to 55°C simulating 1 year of clinical use. Flexural strength (MPa), impact strength (KJ/m² ), hardness (VHN), and surface roughness (μm) were measured using universal testing machine, Charpy's impact tester, Vickers hardness tester, and profilometer, respectively. Data were analyzed by ANOVA and Tukey honestly significant difference (HSD) test (α = 0.05).

RESULTS

The values of flexural strength (MPa) were 86.63 ± 1.0 and 69.15 ± 0.88; impact strength (KJ/m² )-6.32 ± 0.50 and 2.44 ± 0.31; hardness (VHN)-41.63 ± 2.03 and 34.62 ± 2.1; and surface roughness (μm)-0.18 ± 0.01 and 0.12 ± 0.02 for heat-polymerized and 3D-printed denture base materials, respectively. Significant differences in all tested properties were recorded between heat-polymerized and 3D-printed denture base materials (P < 0.001). Thermal cycling significantly lowered the flexural strength (63.93 ± 1.54 MPa), impact strength (2.40 ± 0.35 KJ/m² ), and hardness (30.17 ± 1.38 VHN) of 3D-printed resin in comparison to thermal cycled heat-polymerized resin, but surface roughness showed non-significant difference (p = 0.262).

CONCLUSION

3D-printed resin had inferior flexural strength, impact strength, and hardness values than heat-polymerized resin, but showed superior surface roughness. Temperature changes (thermal cycling) significantly reduced the hardness and flexural strength and increased surface roughness, but did not affect the impact strength.

Comparison of CAD/CAM and Conventional Denture Base Resins: A Systematic Review

At present, complete dentures (CDs) remain the only treatment available for the majority of edentulous patients. CDs are primarily fabricated using a conventional method using polymethylmethacrylate (PMMA) resin. The steps involved in PMMA polymerisation directly affect the quality of the resin prosthetic base and any error reduces retention and occlusal accuracy of CDs. Furthermore, when using the conventional technique, the residual monomer alters the resin mechanical properties and may cause mucosal reactions. Recently, computer aided design and computer aided manufacture (CAD/CAM) techniques were increasingly used to fabricate CDs by machining resin discs that have been manufactured under high pressure and temperature. This systematic review compares CAD/CAM and conventional CDs according to their mechanical, physical and chemical characteristics, as well as the clinical impact of any differences between them. A review was conducted according to the preferred reporting items for systematic reviews and meta-analyses checklist on 392 publications from both PubMed and backward research. Fifteen studies have been included. Results showed that CAD/CAM resins had globally better physical and mechanical properties than conventional resins. The use of machined resin could improve the clinical performance, maintenance and longevity of CDs. Further studies in clinical use would be required to complement these results.

Mechanical properties of polymethyl methacrylate as a denture base: Conventional versus CAD-CAM resin - A systematic review and meta-analysis of in vitro studies

STATEMENT OF PROBLEM

The development of polymethyl methacrylate (PMMA) computer-aided design and computer-aided manufacturing (CAD-CAM) resin blocks with reported improved mechanical properties has simplified complete denture production. However, whether the objective of improved mechanical properties has been achieved compared with conventional heat-polymerized PMMA is not yet clear.

PURPOSE

The purpose of this systematic review and meta-analysis was to evaluate the mechanical properties of denture base resins manufactured by conventional heat-polymerization and by CAD-CAM in terms of flexural strength, flexural modulus, and surface roughness.

MATERIAL AND METHODS

Electronic databases (PubMed/MEDLINE, Scopus, Web of Science) were independently searched by 2 researchers for relevant studies published up to November 2020. The population, intervention, comparison, and outcome (PICO) question was, "Does the conventionally manufactured, heat-polymerized PMMA resin, as a denture base, demonstrate the same mechanical properties as the CAD-CAM resin block?" In addition, a meta-analysis was based on the inverse variance method. Flexural strength, flexural modulus, and surface roughness were analyzed through the continuous outcome evaluated by mean difference and standard deviation, with 95% confidence intervals. To evaluated heterogeneity, the I² value (≤25%=low, ≥50%=moderate and ≥75%=high) and the P value were considered. P<.10 indicated statistical difference for heterogeneity. The effects of meta-analysis were based on the results of heterogeneity as per the studies.

RESULTS

Thirteen in vitro studies were included in the analysis. A total of 507 specimens were evaluated, 222 conventional and 285 CAD-CAM. In terms of flexural strength, the data showed no significant difference when conventional heat-polymerized PMMA was compared with CAD-CAM PMMA resins (P=.06; mean difference=18.28; 95% confidence interval:-0.42 to 36.97). In terms of flexural modulus, there was a significant difference for the CAD-CAM PMMA group (P=.01; mean difference=589.22; 95% confidence interval: 117.95 to 1060.48). In terms of surface roughness, a significant difference was observed between the groups (P=.02; mean difference=-0.53; 95% confidence interval: -0.97 to -0.09) with the conventional heat-polymerized PMMA resin having higher surface roughness values.

CONCLUSIONS

The mechanical properties of CAD-CAM PMMA resins were generally improved when compared with heat-polymerized polymethyl methacrylate resin.

Comparison of Fracture Resistance in Thermal and Self-Curing Acrylic Resins-An In Vitro Study

Thermal and self-curing acrylic resins are frequently and versatilely used in dental medicine since they are biocompatible, have no flavor or odor, have satisfactory thermal qualities and polishing capacity, and are easy and fast. Thus, given their widespread use, their fracture resistance behavior is especially important. In this research work, we comparatively analyzed the fracture resistance capacity of thermo and self-curing acrylic resins in vitro. Materials and Methods: Five prosthesis bases were created for each of the following acrylic resins: Lucitone®, ProBase®, and Megacryl®, which were submitted to different forces through the use of the CS^® Dental Testing Machine, usually mobilized in the context of fatigue tests. To this end, a point was defined in the center of the anterior edge of the aforementioned acrylic resin bases, for which the peak tended until a fracture occurred. Thermosetting resins were, on average, more resistant to fracture than self-curable resins, although the difference was not statistically significant. The thermosetting resins of the Lucitone® and Probase® brands demonstrated behavior that was more resistant to fracture than the self-curing homologues, although the difference was not statistically significant. Thermosetting resins tended to be, on average, more resistant to fracture and exhibited the maximum values for impact strength, compressive strength, tensile strength, hardness, and dimensional accuracy than self-curing resins, regardless of brand.

A Full Digital Workflow for the Duplication of an Existing Implant Retained Overdenture Prosthesis: A Novel Approach

The purpose of this clinical case report is to describe a fully digital workflow for the duplication of an existing implant retained overdenture, highlighting the benefits of digitally fabricated dentures. The patient presented with an existing mandibular implant retained overdenture on Locator attachments that needed to be replaced. The existing overdenture was duplicated/scanned with the use of an intraoral scanner and was 3D printed using acrylic resin. This resin duplicate was sectioned in the midline and served as a unilateral record base to digitally record maxillo-mandibular relationship. The occlusal relationship was scanned unilaterally with the record base (sectioned duplicate) in place, and the procedure was repeated for the opposite side. All scans (edentulous, bite registrations and preliminary scan) were superimposed and the software managed to position and stich everything together. A try-in copy denture (ProArtCAD Try in, Ivoclar Vivadent AG, Schaan, Liechtenstein) was milled in order to imitate the conventional wax teeth try-in. A definitive milled overdenture was fabricated and delivered. A reinforcing polyetheretherketone mesh was fabricated, utilizing computer assisted design/computer assisted manufacturing technology and was incorporated into the pre-designed customized space into the polymethylmethacrylate base, using indirect light-polymerized nano-filled composite resin (crea.lign; bredent GmbH & Co. KG). Occlusion was verified and the patient was instructed oral hygiene, home maintenance and was informed for the required recall visits.

A systematic review of digital removable partial dentures. Part II: CAD/CAM framework, artificial teeth, and denture base

PURPOSE

This study comprehensively reviewed the current status of the digital workflow of removable partial dentures (RPDs) and summarized information about the fabrication methods and material properties of the dental framework, artificial teeth, and denture base.

STUDY SELECTION

We performed a systematic review of the literature published in online databases from January 1980 to April 2020 regarding RPD fabrication and materials used in the related digital technology. We selected eligible articles, retrieved information regarding digital RPDs, and conducted qualitative/quantitative analyses. In this paper, the computer-aided design/computer-aided manufacturing (CAD/CAM) framework, artificial teeth, and denture base materials are reported.

RESULTS

A variety of materials, such as cobalt-chromium alloy, titanium, zirconia, and polyether ether ketone, are used for dental CAD/CAM frameworks. The mechanical strength of the metal materials used for the CAD/CAM framework was superior to that of the cast framework. However, the fitness and surface roughness of the framework and clasp fabricated using a selective laser melting (SLM) method were not superior to those obtained via cast fabrication. Most material properties and the surface roughness of poly methyl methacrylate (PMMA) discs used for digital RPDs were superior to those of heat-cured PMMA.

CONCLUSIONS

The use of a CAD/CAM framework and PMMA disc for digital RPDs offers numerous advantages over conventional RPDs. However, technical challenges regarding the accuracy and durability of adhesion between the framework and denture base remain to be solved. In digital fabrication, human technical factors influence the quality of the framework.

Complete denture fabrication with polyetherketoneketone as a framework material: A clinical report

This clinical report describes the fabrication of conventional complete dentures with polyetherketoneketone (PEKK) frameworks made with computer-aided design and computer-aided manufacturing (CAD-CAM). No biologic or prosthetic complications were observed at the 1-year follow-up.

Should Digital Complete Dentures Be Part of A Contemporary Prosthodontic Education?

Digital complete dentures should be incorporated into a contemporary dental school education due to factors that include the substantial increase in the number of scientific publications devoted to digital dentures, the increased number of companies producing these prostheses, and the expanded use by practitioners. These factors increased recently due to multiple advantages of digital dentures that are described. Based on positive clinical experiences with such prostheses, preclinical curriculum changes were made with examples presented of both didactic and laboratory courses that now include digital dentures. Perspectives are presented regarding online laboratory procedures where a substantial portion can be performed at home through remote instruction.

Combination of Digital and Conventional Workflows in the CAD/CAM-Fabrication of an Implant-Supported Overdenture

Completely digital workflows for the fabrication of implant-supported removable restorations are not yet common in clinical dental practice. The aim of the current case report is to illustrate a reliable and comfortable workflow that reasonably merges conventional and digital workflows for the CAD/CAM-fabrication of implant-supported overdentures. The 53-year old patient was supplied with a digitally processed complete denture in the upper jaw and, simultaneously, with an overdenture supported by four interforaminal implants in the lower jaw. The overdenture included a completely digitally processed and manufactured alloy framework that had been fabricated by selective laser sintering. The case report indicates that digital manufacturing processes for extensive and complex removable restorations are possible. However, as it is currently not yet possible to digitally obtain functional impressions, future developments and innovations might focus on that issue.

Two-visit CAD/CAM milled dentures in the rehabilitation of edentulous arches: A case series

Computer-aided design-computer-aided manufacturing (CAD-CAM) has now found its place in the field of removable prosthodontics with the advent of its use in the fabrication of complete dentures. The conventional technique, by injection or compression molding using heat-polymerized resins, requires cumbersome laboratory procedures and up to five patient visits. For patients with time constraints and clinicians with a higher throughput rate, the CAD-CAM approach with a digital workflow can reduce the number of appointments and ensure speedy delivery of the prosthesis. This article describes the rehabilitation of completely edentulous arches using the Baltic Denture System (Merz Dental GmbH^®) in just two patient visits.

Evaluation of Flexural Strength of Different Denture Base Materials Reinforced with Different Nanoparticles

PURPOSE

To evaluate the effect of adding Al₂ O₃ , SiO₂ , and TiO₂ nanoparticles in ratios of 1, 3, and 5 wt% to different acrylic resins on flexural strength.

MATERIALS AND METHODS

A total of 210 specimens were prepared in 30 groups (n = 7/group) (Control, 1% Al₂ O₃ , 3% Al₂ O₃ , 5% Al₂ O₃ , 1% SiO₂ , 3% SiO₂ , 5% SiO₂ , 1% TiO₂ , 3% TiO₂ , 5% TiO₂ ). The specimens were polished with 200-, 400-, and 600-grit abrasive paper to provide a standard surface before testing and then suspended in distilled water for 30 days. Flexural strength was measured via three-point bending tests. Subsequently, SEM analysis was performed for one specimen from each group. Homogeneity of data was assessed by Kolmogov-Smirnov test followed by two-way ANOVA and Tukey HSD tests (α = 0.05).

RESULTS

There was a significant increase in the flexural strength of polymethylmethacrylate (PMMA) after addition of 1% nanoparticles in both heat-polymerized and autopolymerized acrylic resins (p ˂ 0.05). The flexural strength values of the groups to which Al₂ O₃ and TiO₂ nanoparticles were added exceeded those of the group with SiO₂ addition (p ˂ 0.05). The electron microscopy images revealed that the nanoparticles were more homogeneously dispersed in PMMA with higher flexural strength.

CONCLUSIONS

The mechanical properties of PMMA can be improved by the addition of nanoparticles to PMMA; however, the flexural strength values of PMMA decrease with the addition of nanoparticles at higher percentages (3-5%). Hence, the ideal filler ratio corresponds to 1%.