Trueness assessment of additively manufactured maxillary complete denture bases produced at different orientations

Abstract

Statement of problem: The trueness of the intaglio surface of an additively manufactured maxillary denture base may be influenced by the build orientation and the inclusion of support struts.

Purpose: The purpose of this in vitro study was to compare the trueness of a photopolymer additively manufactured maxillary complete denture base created at different orientations with different support strut designs. Optimizing the build is critical for adopting best practice when fabricating maxillary complete dentures through additive manufacturing techniques.

Material and methods: Denture bases (N=70) were additively manufactured at 5 different build orientations (0-, 15-, 45-, 60-, and 90-degrees) with 10 specimens per orientation. Another 2 groups of 10 were manufactured by using the optimal printing orientation with and without support struts. The denture bases were scanned after storage in artificial saliva at 37 °C, and the scan data were analyzed with a 3D metrology software program. Statistical differences were determined with 1-way analysis of variance (ANOVA) and the Kruskal-Wallis test (α=.05). Color deviation heat maps were used to determine areas of clinically significant dimensional errors.

Results: Significant differences were found among groups for positive mean deviation (F=44.09, P<.001), negative mean deviation (F=11.69, P<.001), and root mean square deviation (F=17.11, P<.001) for the different orientations. One-way ANOVA revealed significant differences with the use of support struts in relation to negative mean deviation (F=3.857, P<.001) and RMSE (F=11.215, P<.001) and positive mean deviation (Kruskal-Wallis H=0.070, P=.007). The color deviation maps showed that a 45- to 90-degree print orientation was truest overall and that the addition of support struts to the cameo and intaglio surfaces improved the trueness of the maxillary denture bases.

Conclusions: The build orientation and inclusion of support struts influenced the accuracy of the intaglio surface of additively manufactured maxillary denture bases. A 45- to 90-degree build orientation with support struts on the cameo and intaglio surfaces resulted in the truest denture base.