Comparison Accuracy of Complete Denture Base Fabrication by CAD/CAM Milled Technique and 3D-Printed: An In Vitro Study

Abstract

Background and objectives: With the advent of computer-aided design and computer-aided manufacturing, a novel technique for fabricating complete dentures has evolved. Digital complete denture fabrication can be accomplished by an additive or subtractive approach which minimal distortion during processing contributes to effective denture base adaption, which leads to good denture retention. The aim of this study was to compare the accuracy of milled and 3D-printed complete denture bases. Materials and Methods: The reference edentulous maxillary arch model was scanned to generate virtual denture bases using computer-aided manufacturing (CAD) software that exports as standard tessellation language (STL) files. Denture bases were constructed using a milling and printing technique called digital light processing (DLP) (10 specimens per technique). Denture bases' intaglio surfaces were scanned and superimposed on the reference model. The accuracy was quantified as root mean square error (RMSE) and evaluated statistically using independent T-test comparisons with a significance level of 0.05. Results: The measurement area was divided into three regions. Milled dentures were significantly more accurate than 3D-printed dentures in the overall intaglio area and primary bearing area of denture bases. Denture bases printed demonstrated significantly greater accuracy than milling dentures in the peripheral/posterior palatal seal area. Conclusion: According to the study's findings, milled dentures fit better in the overall and primary stress-bearing areas than 3D-printed dentures, while 3D-printed dentures appeared more accurate in the peripheral seal area.