Purpose: We evaluated the effects of build orientation and bar addition between lingual flanges on the accuracy of mandibular denture bases fabricated using a digital light processing (DLP) device.
Methods: Mandibular denture bases with and without a bar at the lingual flanges were virtually designed and assigned to eight build orientations. Six dentures per condition were fabricated using a DLP device with a methacrylate-based photopolymerizable monomer (Dima Print denture base) (n=96). The fabricated denture surfaces were digitized, and intaglio surfaces were obtained. These digitized surfaces were compared via superimposition using graphical software (Artec studio12 profession) to their original designed files, and root mean square estimates were obtained. The trueness of the entire and intaglio data was statistically analyzed non-parametrically.
Results: The range of trueness of the entire and intaglio denture bases was 0.15-0.31 mm and 0.11-0.38 mm, respectively. The trueness at 135° and 270° for the entire denture base and that at 270° for the intaglio data without the bar were significantly lower than those for the other build orientations. The trueness at 270° was <0.15 mm irrespective of the conditions. The trueness with the bar of all build orientations, except that of 0° for intaglio data, was significantly smaller than or equal to the trueness without the bar of the corresponding build orientations.
Conclusions: Build orientation and bar addition influenced the accuracy of the complete dentures fabricated using DLP. A build orientation of 270° is recommended for fabricating a mandibular complete denture, irrespective of the bar addition.
Keywords: Accuracy; Adding bar; Build orientation; Complete denture; Digital light projection.