Effect of support structures on the trueness and precision of 3D printing dentures: An in vitro study.

Purpose Additive manufacturing has revolutionized the fabrication of complete dentures. However, this process involves support structure, which is a construction part that holds the specimen during printing, and may prove to be disadvantageous. Therefore, this in vitro study compared the effect of support structure reduction on various volume and area distributions of a 3D-printed denture base to determine optimal parameters based on accuracy.Methods A complete maxillary denture base construction file was used as reference. Twenty denture bases were 3D printed under four conditions (total n=80): no support structure reduction (control), palatal support structure reduction (Condition P), border support structure reduction (Condition B), and palatal and border support structure reduction (Condition PB). Printing time and resin consumption were also recorded. The intaglio surface trueness and precision of all acquired data were exported to a 3D analysis software, and the dimensional changes to the denture base were analyzed using the root-mean-square estimate (RMSE) to assess geometric accuracy and generate color map patterns. Nonparametric Kruskal-Wallis and Steel-Dwass tests (α=0.05) analyzed the accumulated data.Results Control had the lowest RMSE values for trueness and precision. Nevertheless, it demonstrated a significantly lower RMSE than that of Condition B (P=0.02) in precision. Owing to negative deviation at the palatal region, Conditions P and PB had higher retention than Control and Condition B regarding the color map pattern.Conclusions Within the limitations of this study, the reduction of palatal and border support structures showed optimal accuracy with resource and cost savings.

Stress distribution of one-piece and two-piece mini-Implant overdentures with various attachment systems and diameters: A finite element analysis.

PURPOSE: We investigated and compared the stress distribution within one- and two-piece mini-implants for overdentures with three different attachments (ball, Locator, and magnet) and two different diameters using three-dimensional finite element (3D FE) analysis and a monotonic bending test. The goal was to identify the most beneficial implant attachment system design for mini-implant overdentures with a lower risk of implant fracture. METHODS: Twelve 3D FE models simulating a mandible segment with one- and two-piece mini-implants with different attachment systems, diameters, and overdentures were created using three-dimensional computer-aided design (CAD) software. Vertical and oblique forces (45° to the longitudinal axis of the implant) of 100 N were applied to the dentures. The stress distribution was analyzed. A bending test was performed on a mini-implant (Locator, 2.4 mm) using a testing machine to quantify the load at yield stress. RESULTS: One-piece mini-implants showed lower maximum stress compared to two-piece mini-implants. Among the three designs, the magnet attachment systems showed the maximum stress. The maximum von Mises stress occurred at the neck of the implants, which was surrounded by cortical bone in all models, and under both loading conditions. CONCLUSIONS: Focusing on the attachments and one- and two-piece designs of mini-implant overdentures using CAD models to reduce confounding factors affecting the stress distribution, we concluded that one-piece mini-implants tended to show lower stress compared to two-piece mini-implants. Mini-implant overdentures with Locator and ball attachments demonstrated lower stress within the implants compared to those with magnet attachments under vertical and oblique loading conditions.