Accuracy of Digitally Fabricated Wax Denture Bases and Conventional Completed Complete Dentures

The purpose of this investigation was to analyze the accuracy of digitally fabricated wax trial dentures and conventionally finalized complete dentures in comparison to a surface tessellation language (STL)-dataset. A generated data set for the denture bases and the tooth sockets was used, converted into STL-format, and saved as reference. Five mandibular and 5 maxillary denture bases were milled from wax blanks and denture teeth were waxed into their tooth sockets. Each complete denture was checked on fit, waxed onto the dental cast, and digitized using an optical laboratory scanning device. The complete dentures were completed conventionally using the injection method, finished, and scanned. The resulting STL-datasets were exported into the three-dimensional (3D) software GOM Inspect. Each of the 5 mandibular and 5 maxillary complete dentures was aligned with the STL- and the wax trial denture dataset. Alignment was performed based on a best-fit algorithm. A three-dimensional analysis of the spatial divergences in x-, y- and z-axes was performed by the 3D software and visualized in a color-coded illustration. The mean positive and negative deviations between the datasets were calculated automatically. In a direct comparison between maxillary wax trial dentures and complete dentures, complete dentures showed higher deviations from the STL-dataset than the wax trial dentures. The deviations occurred in the area of the teeth as well as in the distal area of the denture bases. In contrast, the highest deviations in both the mandibular wax trial dentures and the mandibular complete dentures were observed in the distal area. The complete dentures showed higher deviations on the occlusal surfaces of the teeth compared to the wax dentures. Computer-aided design/computer-aided manufacturing (CAD/CAM)-fabricated wax dentures exhibited fewer deviations from the STL-reference than the complete dentures. The deviations were significantly greater in the vicinity of the denture teeth area and the bases. The conventional transfer of CAD/CAM-fabricated wax dentures into acrylic resin leads to the highest deviations from the STL-reference.