Evaluation of ridge lap accuracy and adaptation of the diagnostic tooth arrangement fabricated with CAD-CAM systems: An in vitro study.

STATEMENT OF PROBLEM: Digital light processing (DLP) and milling (MIL) are computer-aided design and computer-aided manufacturing (CAD-CAM) systems that have become popular for fabricating definitive complete dentures. However, few studies have compared the accuracy of the ridge laps of diagnostic tooth arrangements fabricated with these systems and their adaptation with the denture base sockets. PURPOSE: The purpose of this in vitro study was to comparatively analyze the accuracy of the ridge laps of the diagnostic tooth arrangements fabricated by using MIL and different layer thicknesses in DLP. MATERIAL AND METHODS: A virtual definitive complete denture was designed with a CAD software program on a scanned virtual digital cast, divided into diagnostic tooth arrangement and a denture base that accommodated the arrangement, and saved as a standard tessellation language (STL) file. From this file, 27 diagnostic tooth arrangements were fabricated by DLP (50 µm and 100 µm) and MIL. The ridge laps were scanned and overlapped on the file (reference data) to analyze the accuracy (trueness and precision). The ridge laps of all groups were overlapped on the reference denture base data to analyze their adaptation with the sockets. The measurements of the trueness, precision, and adaptation were analyzed statistically by using the nonparametric Kruskal-Wallis test and post hoc Mann-Whitney U test with Bonferroni correction. RESULTS: The diagnostic tooth arrangements showed significant differences among the groups (P<.001). The values were the lowest in the MIL group and highest in the DLP group for the following parameters: trueness root-mean-square (RMS) value, 173 ±7 µm versus 286 ±15 µm; precision RMS value, 22 ±3 µm versus 57 ±20 µm; and adaptation RMS value, 41 ±5 µm versus 112 ±13 µm. CONCLUSIONS: Of the 2 diagnostic tooth arrangements fabricated with the CAD-CAM systems, the one fabricated with MIL was clinically more appropriate.

Evaluation of trueness in a denture base fabricated by using CAD-CAM systems and adaptation to the socketed surface of denture base: An in vitro study.

STATEMENT OF PROBLEM: Computer-aided design and computer-aided manufacturing (CAD-CAM) systems are increasingly used to fabricate removable complete dentures. However, comparisons and analyses of the trueness and adaptation of the socketed surface of denture bases produced by milling (MIL) and digital light processing (DLP) are lacking. PURPOSE: The purpose of this in vitro study was to evaluate and compare the trueness and socketed surface adaptation of denture bases fabricated by using additive and subtractive manufacturing. MATERIAL AND METHODS: Based on a denture base standard tessellation language (STL) file, a total of 15 denture bases were produced by using DLP (horizontal and vertical direction) and MIL. The intaglio and cameo surfaces of the fabricated denture bases were scanned with a dental scanner. The scanned intaglio and cameo surfaces were overlapped with the corresponding reference denture base STL file for trueness evaluation. In addition, the ridge lap STL file of the diagnostic tooth arrangement, in which reverse normal was performed, was superimposed on the socketed surface of the denture base of all groups to evaluate adaptation. RESULTS: The root mean square (RMS) values of trueness and adaptation showed statistically significant differences (P<.05). For the trueness RMS value of the intaglio surface of the denture base, the MIL-denture base (MDB) group had the lowest value of 150 ±6 µm, whereas the vertical denture base (VDB) of the DLP group was the largest with 328 ±4 µm. For the trueness RMS value of the cameo surface, the MDB group was the lowest with 50 ±1 µm, whereas the VDB group was the largest with 334 ±24 µm. For the adaptation RMS value of the socketed surface of the denture base, the MDB group was the lowest with 44 µm, whereas the VDB group was the largest with 117 ±2 µm. CONCLUSIONS: Within the limits of this in vitro study, the MDB group showed better trueness and socketed surface adaptation than the DLP groups (HDB and VDB).

Effect of layer thickness setting on the adaptation of stereolithography apparatus-fabricated metal frameworks for removable partial dentures: An in vitro study.

STATEMENT OF PROBLEM: A staircase effect is noted in the fabrication of metal frameworks for removable partial dentures (RPDs) when using stereolithography apparatus (SLA). It affects the adaptation of the definitive metal framework depending on the layer thickness setting. However, studies on the effect of the layer thickness setting on the adaptation of metal frameworks are lacking. PURPOSE: The purpose of this in vitro study was to determine the optimal layer thickness through comparative analysis of the adaptation of SLA-fabricated metal frameworks with different layer thickness settings. MATERIAL AND METHODS: A total of 15 metal RPD frameworks were SLA-fabricated by using 3 different layer thickness settings (16 µm, 50 µm, and 100 µm). The adaptation of the frameworks was measured by using the silicone replica technique, sectioned at the canine, first molar, and second molar regions by using a guide. The thickness of the light-body silicone was measured with a digital microscope at 3 points in each of the 3 areas. The measurements of the adaptation were statistically analyzed using the nonparametric Kruskal-Wallis test and post hoc Mann-Whitney U test with Bonferroni correction. RESULTS: The gaps measured in each area showed statistically significant differences in all 3 groups (P<.05). In the anterior, middle, and posterior areas, the 16-µm metal framework group showed the narrowest gaps (207 ±46 µm, 195 ±49 µm, and 188 ±40 µm, respectively). The 3 groups showed statistically significant differences in total gaps in the RPD frameworks relative to the layer thickness settings (P<.05); the total gap was lowest (197 ±42 µm) for the 16-µm group. CONCLUSIONS: For SLA, 50 µm is the recommended layer thickness considering the effect of layer thickness settings on the adaptation of the RPD framework and the fabrication time.

Evaluating the accuracy (trueness and precision) of interim crowns manufactured using digital light processing according to post-curing time: An in vitro study.

PURPOSE: This study aimed to compare the accuracy (trueness and precision) of interim crowns fabricated using DLP (digital light processing) according to post-curing time. MATERIALS AND METHODS: A virtual stone study die of the upper right first molar was created using a dental laboratory scanner. After designing interim crowns on the virtual study die and saving them as Standard Triangulated Language files, 30 interim crowns were fabricated using a DLP-type 3D printer. Additively manufactured interim crowns were post-cured using three different time conditions-10-minute post-curing interim crown (10-MPCI), 20-minute post-curing interim crown (20-MPCI), and 30-minute post-curing interim crown (30-MPCI) (n = 10 per group). The scan data of the external and intaglio surfaces were overlapped with reference crown data, and trueness was measured using the best-fit alignment method. In the external and intaglio surface groups (n = 45 per group), precision was measured using a combination formula exclusive to scan data (10C2). Significant differences in accuracy (trueness and precision) data were analyzed using the Kruskal-Wallis H test, and post hoc analysis was performed using the Mann-Whitney U test with Bonferroni correction (α=.05). RESULTS: In the 10-MPCI, 20-MPCI, and 30-MPCI groups, there was a statistically significant difference in the accuracy of the external and intaglio surfaces (P <.05). On the external and intaglio surfaces, the root mean square (RMS) values of trueness and precision were the lowest in the 10-MPCI group. CONCLUSION: Interim crowns with 10-minute post-curing showed high accuracy.

Effect of rinsing time on the accuracy of interim crowns fabricated by digital light processing: An in vitro study.

PURPOSE: This study was to evaluate the effect of rinsing time on the accuracy of interim crowns fabricated by digital light processing. MATERIALS AND METHODS: The maxillary right first molar master die was duplicated using a silicone material, while a study die was produced using epoxy resin. Scans of the epoxy resin die were used in combination with CAD software to design a maxillary right first molar interim crown. Based on this design, 24 interim crowns were fabricated with digital light processing. This study examined the trueness and precision of products that were processed with one of the three different postprocessing rinsing times (1 min, 5 min, and 10 min). Trueness was measured by superimposing reference data with scanned data from external, intaglio, and marginal surfaces. Precision was measured by superimposing the scan data within the group. The trueness and precision data were analyzed using Kruskal-Wallis, nonparametric, and post-hoc tests, and were compared using a Mann-Whitney U test with Bonferroni correction (α=.05). RESULTS: The trueness of the external and intaglio surfaces of crowns varied significantly among the different rinsing times (P =.004, P =.003), but there was no statistically significant difference in terms of trueness measurements of the marginal surfaces (P =.605). In terms of precision, statistically significant differences were found among the external, intaglio, and marginal surfaces (P =.001). CONCLUSION: Interim crowns rinsed for 10 minutes showed high accuracy.

Evaluation of the adaptation of complete denture metal bases fabricated with dental CAD-CAM systems: An in vitro study.

STATEMENT OF PROBLEM: Conventional fabrication of complete denture metal bases is being replaced by the computer-aided design and computer-aided manufacturing (CAD-CAM) systems. However, a comparative analysis of subtractive and additive CAD-CAM manufacturing techniques is lacking. PURPOSE: The purpose of this in vitro study was to compare the adaptation of complete denture metal bases fabricated by milling (subtractive manufacturing) and stereolithography apparatus (SLA) and digital light processing (DLP) (additive manufacturing). MATERIAL AND METHODS: Thirty metal bases were manufactured by using the milling (MIL group), SLA (SLA group), and DLP (DLP group) techniques. The silicone replica technique was used to evaluate the adaptation of the complete denture metal bases, and 30 silicone blocks were fabricated. The silicone block was cut equally in the canine, first molar, and second molar areas. The gap between the model and the metal base was measured by using a digital microscope at the 3 locations, and the measured data were statistically analyzed by using a statistical software program (α=.05). RESULTS: The gaps measured at the 3 areas showed significant differences in all 3 groups (P<.05). At the anterior, middle, and posterior areas, the SLA group showed the narrowest gap (302 ±31 µm, 241 ±39 µm, 201 ±43 µm, respectively). The SLA group also had the narrowest total gap of the metal bases (218 ±33 µm). CONCLUSIONS: The adaptation of the fabricated metal bases varied significantly across the techniques used but fell within a clinically allowable range. The SLA group was the most precise in the fabrication of complete denture metal bases. Further studies are required to analyze the effects of the layer thickness setting, wax elimination, and casting temperature on the adaptation of metal bases manufactured by using SLA.

Evaluation of the accuracy (trueness and precision) of a maxillary trial denture according to the layer thickness: An in vitro study.

STATEMENT OF PROBLEM: Layer thickness in additive manufacturing has stair-step effects that greatly affect the accuracy of the definitive prosthesis. Although the layer thickness can be set, insufficient data comparing and analyzing the accuracy of the fabricated prosthesis after adjusting the layer thickness are available. PURPOSE: The purpose of this in vitro study was to evaluate and compare the accuracy of trial dentures fabricated with different layer thicknesses by using stereolithography (SLA) apparatus. MATERIAL AND METHODS: A maxillary complete edentulous cast was duplicated with silicone material to make a master gypsum cast which was scanned by using a laboratory scanner and saved as a standard tessellation language (STL) file. This was exported into a computer-aided design software program to produce and store the trial denture. Twenty dentures were fabricated according to the set layer thicknesses (50 µm and 100 µm) by using the SLA. The trueness was measured by scanning the intaglio and cameo surfaces to find the best overlap with the reference model to obtain the root mean square value. The precision was evaluated based on the RMS value gained by superimposing the identical scan data from each group and using the combination formula. The Mann-Whitney U-test was used to confirm significant differences among the groups (α=.05). RESULTS: The trueness of the 50-µm-SLA trial denture and the 100-µm-SLA trial denture was significantly different for the intaglio and cameo surfaces (P<.05). However, the intaglio surface did not show a statistically significant difference (P=.987) for precision, but the cameo surface did (P<.05). CONCLUSIONS: It is clinically more appropriate to set the layer thickness to 100 µm rather than 50 µm for the fabrication of accurate trial dentures by using SLA.