3D Printing of Complete Dentures: A Narrative Review.

To explore the applications of 3D printing for the fabrication of complete dentures, a literature search was conducted using PubMed to identify articles related to the topic of 3D-printed complete dentures. A search was conducted that included the following keywords: digital complete denture workflow, printed complete denture, additive manufacturing complete denture, digital complete denture, CAD/CAM complete denture. Articles published before 2016 were excluded to increase the relevancy of reporting results. Determining how 3D-printed dentures compare to conventional and milled dentures is important to better understand how they can be used clinically. Material strength, color stability, and denture base adaptation are discussed. Currently, the area of greatest innovation is with printing resins and improving physical and esthetic properties. As with every innovation, multiple generations of materials are created before the gold standard is achieved. While the ideal printed denture material does not currently exist, based on the published research, printed dentures have material strength that meets ISO standards, with denture base adaptation similar to conventionally processed dentures. Clinically, it is likely that printed dentures will have more challenges with fractures, color stability, and staining. However, printed dentures offer many benefits, and the current limitations will be addressed as new materials are developed. We are currently at the beginning of what is an exciting future for printed dentures.

Comparing the accuracy of occlusal vertical dimension transfer in CAD-CAM dentures.

PURPOSE: There are different methods to transfer occlusal vertical dimension (OVD) when fabricating complete dentures, but it is not clear which method yields the most accurate transfer. This study investigated the accuracy of transferring the OVD of the maxillary/mandibular relationship when designing and fabricating digital dentures by evaluating two commonly used workflows: duplicate dentures (DDs) and occlusion rims (ORs). MATERIALS AND METHODS: Mounted edentulous casts were used to simulate a completely edentulous patient. These casts were used in two workflows: (1) DD workflow where complete dentures were fabricated and relined (n = 15), and (2) OR where final impressions and ORs were constructed (n = 15). Relined dentures and ORs with fiduciary markers were then scanned and virtually articulated, then exported as STL files. A scan of the articulated casts (simulated patients) with fiduciary markers embedded was also exported as an STL file and used as a control. STL files for each workflow were superimposed over the control and analyzed in 3D inspection software (Geomagic Control X, 3D Systems, NC) for deviations (mm) at three different locations. Average 3D deviations were compared among the groups using a two-way ANOVA (α-0.05). RESULTS: The average deviation for OR was significantly larger than DD at all locations of measurement [F = 46.00, p < 0.0001]. The majority of the measurements (98.9%) had a positive deviation value, indicating increased OVD. The overall deviation for the OR group from the control was 0.72 ± 0.13 mm versus 0.45 ± 0.23 mm for the DD group. There was no difference in deviation between the points of measurement and no interaction between the location and method [F = 0.02, p < 0.98]. CONCLUSIONS: The DD workflow exhibited less deviation in the transfer of OVD than the OR workflow. However, the deviation was small and may not be clinically significant.

Evaluation of Marginal and Internal Fit of Ceramic Laminate Veneers Fabricated with Five Intraoral Scanners and Indirect Digitization.

The long-term success of ceramic laminate veneers (CLVs) is influenced by the marginal and internal fit of the restorations. However, studies comparing the fit of CLVs using different intraoral scanners or the indirect digitization technique are lacking. The purpose of this study was therefore to assess the marginal and internal fit of CAD/CAM-milled CLVs using different intraoral scanners and the indirect digitalization technique. An ivorine typodont maxillary left-central incisor was prepared; the tooth and the neighboring teeth were scanned and used as a template to print ninety 3D partial models. Thereafter, ceramic laminate veneers (CLVs) (N = 90) were milled from IPS-Emax CAD blocks and divided into six equal groups (15 specimens each) according to the type of intraoral scanner (IOS), as follows: Omnicam IOS, SC3600 IOS, Trios 3 IOS, Emerald IOS, I500 IOS. Fifteen further CLVs were fabricated using the conventional indirect digitalization technique. After cementation on the resin dies and embedding in clear epoxy resin, specimens were sectioned inciso-gingivally and mesio-distally. At the incisal and cervical positions, the marginal discrepancy was measured and evaluated in addition to the internal gap at six locations using SEM (200×). Differences between gap measurements among the six groups were determined using ANOVA. Games-Howell multiple comparisons for homogenous variances and LSD multiple comparisons for non-homogenous variances were used with 95% confidence intervals. The significance level was set at 0.05. The lowest mean absolute marginal gap at the incisal margins (AMGI) was recorded for Omnicam group (203.28 ± 80.14) µm, while the highest mean absolute marginal gap at the cervical margins (AMGC) was recorded for Omnicam group (147.16 ± 59.78) µm. The mean AMGC was reported to be significantly different between the conventional technique (146.75 ± 38.43) µm and Trios 3 (91.86 ± (35.51) µm; p = 0.001) and between Emerald (112.37 ± (50.31) µm; p = 0.042) and I500 (86.95 ± (41.55) µm; p < 0.001). The mean MGI was found to be significantly different between the conventional technique (114.11 ± (43.45) µm and I500 group (186.99 ± (73.84) µm) only (p = 0.035). However, no significant differences were found in the mean MGI between all types of IOSs. The means of AMG and MG were significantly different at incisal or cervical areas between the conventional technique and IOSs and within the scanner groups (p > 0.05). Marginal gaps were higher in the incisal region compared to the cervical region with both the indirect digitization technique and the IOSs. Ceramic laminate veneers (CLVs) fabricated using IOSs produced overall internal and marginal fit adaptation results comparable to CLVs fabricated from the indirect digitalization method, and both techniques produced clinically acceptable results.

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.

What Occlusal Scheme Should Be Used with Removable Partial Dentures?

PURPOSE: Multiple clinical studies have been published comparing different philosophies of complete denture occlusion and different types of denture teeth. However, it is unclear whether comparable data are available for occlusal schemes used with removable partial dentures (RPDs). Therefore, this review investigated the dental literature related to occlusal schemes for RPDs. MATERIALS AND METHODS: A PubMed search of English language articles was performed using the term "removable partial denture, occlusion" with 765 results. When the term "occlusion in removable partial prosthodontics" was used there were 784 results. Seventy-four articles were identified using the different search term of "RPD, occlusion" while use of the term "occlusal scheme, with removable partial dentures" listed 18 publications. The term "removable partial denture, occlusion, literature reviews" produced 38 potential publications related to the topic. Using the term "removable partial denture occlusion systematic review" resulted in 2 citations. Using the term "RPD occlusion literature review" resulted in one foreign language manuscript whereas using the term "RPD occlusion systematic review" resulted in one article unrelated to dentistry. The term "clinical studies of RPD occlusion" produced 5 results with none related to the topic. There were 23 results using the term "clinical studies of removable partial denture occlusion" with one potentially related to RPD occlusal schemes. RESULTS: A review of the titles and abstracts revealed 12 articles that appeared to contain specific information about the occlusal scheme used with RPDs. Following a detailed review of those publications, only 4 contained recommendations for RPD occlusion and were included in this review. The available information regarding the recommendations for occlusal schemes in these articles was based on expert opinion. A decision was made to include a hand search of 9 textbooks containing varying amounts of information related to occlusal schemes for RPDs, but no evidence-based references related to RPD occlusal schemes were found in the textbooks. Since this entire review is based on expert opinion, no attempt was made to critique the opinions expressed by these authors but rather to present their perspectives for evaluation by readers. CONCLUSIONS: The occlusion developed with RPDs should be physiologically harmonious, allowing the supporting structures to remain in a good state of health with functional stress distributed among all the occluding teeth. Multiple authors indicate the occlusion in maximum intercuspation/centric occlusion should incorporate bilateral posterior contacts with no deflective occlusal contacts. When most occlusal contacts on natural teeth are missing, it has been proposed that extension base RPDs have their occlusal contacts developed in centric occlusion. Regarding eccentric occlusal relationships, a balanced occlusal scheme has been recommended by multiple authors with one author advocating use of a lingualized balanced. An anterior guided (canine-protected) occlusion has also been recommended when the canines are present and not periodontally compromised. When RPDs oppose a complete denture, several authors indicate a bilateral balanced occlusion should be used to help stabilize the complete denture.

CAD/CAM Complete Denture Systems and Physical Properties: A Review of the Literature.

PURPOSE: CAD/CAM complete dentures have increased in popularity and a wide variety of systems are currently available. These prostheses present many advantages for clinicians, technicians and patients. Subtractive manufacturing is used by most of the available systems while a few manufacturers use an additive manufacturing technique. This article describes the currently available systems and materials available for the fabrication of CAD/CAM complete dentures and reviews the literature relative to their physical properties. METHODS: A comprehensive review of the literature was completed to enumerate the currently available techniques to fabricate CAD/CAM complete dentures and discuss their physical properties. A search of English language peer-reviewed literature was undertaken using MEDLINE and PubMed on research articles published between 2000 and 2019. A hand search of relevant dental journals was also completed. RESULTS: The literature indicates the physical properties of CAD/CAM milled poly(methylmethacrylate) or PMMA as it is commonly described is superior to conventionally processed PMMA for the fabrication of complete dentures. CONCLUSION: The incorporation of CAD/CAM technology into complete denture design and fabrication streamlines the clinical and laboratory processes and provides improved physical properties that enhance denture quality.

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.

Accuracy of 3D Printed Models Created by Two Technologies of Printers with Different Designs of Model Base.

PURPOSE: To evaluate the accuracy of three-dimensional (3D) printed models manufactured using two different printer technologies with different model base designs. MATERIALS AND METHODS: A maxillary typodont was scanned using a desktop scanner to generate the Standard Tessellation Language (STL) file as a reference scan. After the scanning procedure, the STL file was exported to Model Builder™ for designing the following two types of the model bases: a solid base design and a hollow base design with a 2.0 mm thickness of the external shell. Each design was printed to produce 10 models using a Continuous Liquid Interface Production (CLIP) printer and a Digital Light Processing (DLP) printer. The following four groups were tested: CLIP with solid base (CS); CLIP with hollow base (CH); DLP with solid base (DS); and DLP with hollow base (DH). A total of 40 models were scanned using the same desktop scanner to generate the STL files for evaluation of the accuracy by evaluation of trueness and precision. All STL files were superimposed with the control STL file via surface matching software and a comparison was performed using the 3D color mapping function and a 2D comparison of 48 points selected on the tested model. The data were collected by measuring the deviation between the tested model and the reference scan. Trueness was calculated by using the comparison among four tested groups. The Kruskal-Wallis analysis was conducted to assess the overall statistical significance of differences among the tested groups (α = 0.05). For precision measurement, the evaluation was conducted using Intraclass Correlation Coefficient (ICC) value at 95% confident interval to determine the deviation within the same tested groups. RESULTS: The median values for the deviated distance of the four tested groups were 0.045 (CH), 0.035 (CS), 0.077 (DH), and 0.077 mm (DS). There were no statistically significant differences between the trueness of the two groups when using the same printers regardless of the designs of model base (p > 0.05). However, when comparing the two printers using the same model base design and the two different designs of model base, there were statistically significant differences in trueness (p < 0.05). The 3D printed models created using CLIP technology had higher trueness than the DLP technology printer. Precision of the 3D printed model was displayed in ICC value. The ICC values of four tested groups were 0.968 (CH), 0.981 (CS), 0.969 (DH), and 0.983 (DS). All tested groups were classified as exhibiting an excellent level of precision based on 95% confident interval of the ICC estimation. CONCLUSIONS: The accuracy of 3D printed models was affected by the printer technology regardless of whether the model base was solid or hollow. The CLIP technology printer produced significantly less variation from the reference model than the DLP printer. However, all of the 3D printed models were determined to exhibit a clinically acceptable level of accuracy based on the recorded dimensions being less than 100 µm different than the reference model.

Surface Roughness of Monolithic and Layered Zirconia Restorations at Different Stages of Finishing and Polishing: An In Vitro Study.

PURPOSE: To evaluate surface roughness and topography of different zirconia-based restorations at various steps of finishing and polishing. MATERIALS AND METHODS: Seventy-five zirconia discs were fabricated and divided into 3 layered and 2 monolithic groups: layered conventional (VM9; Vita), layered pressed (PM9; Vita), layered digital (TriLuxe Forte; Vita), opaque monolithic (Ceramill Zi; Amann Girrbach), and translucent monolithic (Zolid FX; Amann Girrbach). Surface roughness testing (Ra, Rz) and scanning electron microscopy were performed at the glazed, unglazed, finished, polished, super-polished, and super-polished with diamond paste steps. One-way ANOVA and Tukey tests were used for statistical analysis. RESULTS: There were significant differences in all groups among the different steps (p < 0.001, F = 77.67 for layered conventional; p < 0.001, F = 133.90 for layered pressed; p < 0.001, F = 47.94 for layered digital; p < 0.001, F = 48.05 for zirconia opaque; p < 0.001, F = 43.91 for zirconia translucent). For the layered groups, glazed stage was significantly different from all other steps (p < 0.001). For the layered conventional and digital groups, polishing using diamond paste was not significantly different from the polished and super-polished steps (p = 0.448, p = 0.153), while for the layered pressed group, polishing using diamond paste was not significantly different from the super polished step (p = 0.815). For monolithic groups, there were no significant differences between the polished and super-polished steps (p = 0.957 for zirconia opaque, p = 1.00 for zirconia translucent). Both the diamond paste and super-polished steps showed no significant differences (p = 0.620, p = 0.550) from the glazed surface in the opaque zirconia group. CONCLUSIONS: Surface roughness of monolithic and layered zirconia was improved by polishing; however, only opaque zirconia reached the level of surface roughness of the glazed stage. Type of buildup affected the surface roughness of adjusted ceramics, with monolithic zirconia showing lower surface roughness than layered zirconia. Polishing with diamond paste provided no significant improvement in the surface roughness of monolithic or layered zirconia.

Prosthetic complications with implant prostheses (2001-2017).

AIM: To present recent data regarding prosthetic complications with implant prostheses and crowns as well as compare this data with data presented in a 2003 publication. MATERIAL AND METHODS: An electronic Medline (PubMed) with MeSH terms search was performed, focussing on clinical studies that reported data on prosthetic complications associated with implant fixed complete dentures, implant overdentures, implant fixed partial dentures, and implant single crowns. RESULTS: There were nine prosthetic complications reported with implant fixed complete dentures, 17 with implant overdentures, four with implant fixed partial dentures, and six with implant single crowns. The greatest number of complications and the largest incidence of percentages occurred with implant overdentures. The lowest incidence percentages were recorded for implant single crowns. These findings are in agreement with the previous 2003 publication. It is of interest to note that some of the complications reported previously were not reported in this review, and some complications reported in this review were not listed in the 2003 publication, thereby limiting the number of direct comparisons between this paper and the earlier report. A surprising finding was that some complications associated with implant overdentures from the current data exceeded the incidence in 2003 (reactivation of the retentive attachment; mucosal hyperplasia; and the need for overdenture relines). CONCLUSIONS: Implant overdentures are associated with more complications than implant fixed complete dentures, implant fixed partial dentures, and implant single crowns. The lowest incidence of complications was reported with implant single crowns. The most common complication reported with implant fixed complete dentures was denture tooth fracture. The most common complication associated with implant overdentures was the need for adjustments. Porcelain veneer fracture/chipping was the most common complication identified in the studies of implant fixed partial dentures. The most common complication reported with implant single crowns was abutment screw loosening.

Using Intraoral Scanning to Capture Complete Denture Impressions, Tooth Positions, and Centric Relation Records.

Intraoral scanning was used to capture the soft tissue surfaces of both maxillary and mandibular edentulous ridges and the denture borders. Additionally, an intraoral scanner was used to digitize existing dentures with their tooth positions and base forms and a centric relation record obtained with a Gothic arch-tracing device. These scans provided all the required records for fabrication of computer-aided design/computer-assisted manufacturing of complete dentures.

Using Intraoral Scanning to Fabricate Complete Dentures: First Experiences.

The newest impression techniques use intraoral scanners to capture both the hard and soft tissues. However, with edentulous patients, the accuracy of an intraoral scanner to capture an acceptable impression for the fabrication of a complete denture needs to be evaluated. Therefore, the purpose of this report of two patient treatments is to describe a technique that used intraoral scanning to record mucosal morphology and fabricate computer-aided design/computer-assisted manufacture (CAD/CAM) complete dentures.

Comparison of denture tooth movement between CAD-CAM and conventional fabrication techniques.

STATEMENT OF PROBLEM: Data comparing the denture tooth movement of computer-aided design and computer-aided manufacturing (CAD-CAM) and conventional denture processing techniques are lacking. PURPOSE: The purpose of this in vitro study was to compare the denture tooth movement of pack-and-press, fluid resin, injection, CAD-CAM-bonded, and CAD-CAM monolithic techniques for fabricating dentures to determine which process produces the most accurate and reproducible prosthesis. MATERIAL AND METHODS: A total of 50 dentures were evaluated, 10 for each of the 5 groups. A master denture was fabricated and milled from prepolymerized poly(methyl methacrylate). For the conventional processing techniques (pack-and-press, fluid resin, and injection) a polyvinyl siloxane putty mold of the master denture was made in which denture teeth were placed and molten wax injected. The cameo surface of each wax-festooned denture was laser scanned, resulting in a standard tessellation language (STL) format file. The CAD-CAM dentures included 2 subgroups: CAD-CAM-bonded teeth in which the denture teeth were bonded into the milled denture base and CAD-CAM monolithic teeth in which the denture teeth were milled as part of the denture base. After all specimens had been fabricated, they were hydrated for 24 hours, and the cameo surface laser scanned. The preprocessing and postprocessing scan files of each denture were superimposed using surface-matching software. Measurements were made at 64 locations, allowing evaluation of denture tooth movement in a buccal, lingual, mesial-distal, and occlusal direction. The use of median and interquartile range values was used to assess accuracy and reproducibility. Levene and Kruskal-Wallis analyses of variance were used to evaluate differences between processing techniques (α=.05). RESULTS: The CAD-CAM monolithic technique was the most accurate, followed by fluid resin, CAD-CAM-bonded, pack-and-press, and injection. CAD-CAM monolithic technique was the most reproducible, followed by pack-and-press, CAD-CAM-bonded, injection, and fluid resin. Techniques involving compression during processing showed increased positive occlusal tooth movement compared with techniques not involving compression. CONCLUSIONS: CAD-CAM monolithic dentures produced the best combination of accuracy and reproducibility of the tested techniques. The results from this study demonstrate that varying amounts of tooth movement can be expected depending on the processing technique. However, the clinical significance of these differences is unknown.

Errors associated with digital preview of computer-engineered complete dentures and guidelines for reducing them: A technique article.

Patient reports, clinical studies, and systematic reviews reveal a rapid increase in interest in computer-engineered complete dentures (CECDs). The advantages of CECDs include a reduced number of visits, improved fit and retention, and electronic archiving. However, patient dissatisfaction has been reported with CECDs, which may be due to the lack of a trial placement appointment. This technique article identifies errors that occur when CECDs are previewed digitally and proposes guidelines and a checklist to reduce complications such as inadequate esthetics, poor tooth arrangement, misaligned occlusal plane, and inappropriate denture base characteristics.

Three-dimensional printing in contemporary fixed prosthodontics: A technique article.

Digital dentistry has gained in popularity among clinicians and laboratory technicians because of its versatile applications. Three-dimensional (3D) printing has been applied in many areas of dentistry as it offers efficiency, affordability, accessibility, reproducibility, speed, and accuracy. This article describes a technique where 3D printing is used to fabricate a die-trimmed cast and to replicate gingival tissue and implant analogs. The digital workflow that replaces the conventional laboratory procedure is outlined.

A 3D-printed guide for lateral approach sinus grafting: A dental technique.

Lateral approach sinus grafting has become a routine and predictable surgical method of augmenting the pneumatized sinus for implant placement. Outlining the lateral window access can be a challenging task for the clinician to envision and execute. Improper extension and access to the maxillary sinus can prevent proper placement of graft materials and lead to complications. The purpose of this report was to demonstrate a technique that will allow the precise planning of the lateral approach using radiographic information and 3-dimensional (3D) software to 3D-print a surgical guide.

Clinical complications and quality assessments with computer-engineered complete dentures: A systematic review.

STATEMENT OF PROBLEM: Computer-engineered complete dentures (CECDs) have significant potential as shown by recent reports of outcomes and specific applications. An understanding of complications and quality assessment factors associated with CECDs from compiled data is lacking in published reports. PURPOSE: The purpose of this systematic review was to determine the clinical complications and quality assessments related to CECDs. MATERIAL AND METHODS: Electronic searches of publications in English from January 1984 to September 2016 were performed in MEDLINE and Cochrane databases, with the results enriched by manual searches and citation mining to address 2 population intervention comparison outcome (PICO) questions: what are the clinical complications associated with CECDs, and what are the quality assessments with CECDs? RESULTS: A review of 5 selected articles (limited data) on CECDs revealed patient dissatisfaction related to overall outcome (25.49%), inadequate retention (20.73%), and esthetic concerns (15.09%) as common complications. Quality assessment factors that were used to report complications were identified. CONCLUSIONS: Patient dissatisfaction, inadequate retention, and inadequate esthetics were the most common complications with CECDs. The addition of a trial placement option for CECDs could result in a better clinical outcome, reducing the incidence of other complications related to occlusal vertical dimension, centric relationship, tooth arrangement, and esthetics, improving patient satisfaction, and reducing remakes. The difficulty in reading the digital preview for an objective assessment before fabrication is a unique but not a common, complication for CECDs.