Accuracy of removable partial denture framework fabricated by casting with a 3D printed pattern and selective laser...

Area of Science:

• Biomaterials and Dental Technology
• Additive Manufacturing in Dentistry
• Prosthodontics and Restorative Dentistry

Background:

• Removable partial denture (RPD) frameworks are crucial for restoring oral function and aesthetics.
• Advancements in digital dentistry offer new fabrication methods, including 3D-printed pattern casting and selective laser sintering (SLS).
• Evaluating the accuracy of these novel manufacturing techniques is essential for clinical success.

Purpose of the Study:

• To compare the fabrication accuracy of RPD frameworks produced by 3D-printed pattern casting (AM-Cast) versus those made by selective laser sintering (SLS).
• To identify specific areas of discrepancy between the two manufacturing methods.

Main Methods:

• A partially edentulous mandibular model was scanned, and the RPD framework was designed using CAD software.
• Two fabrication methods were employed: AM-Cast (3D-printed resin pattern followed by casting) and SLS (direct metal laser sintering).
• Fabrication accuracy was assessed by 3D scanning the frameworks, overlapping the data with the design, and statistically comparing discrepancies using the Mann-Whitney U test.

Main Results:

• Both AM-Cast and SLS frameworks exhibited discrepancies compared to the design data, with ranges of -0.185±0.138 to 0.352±0.143mm for AM-Cast and -0.166±0.009 to 0.123±0.009mm for SLS.
• Statistically significant differences in accuracy were noted across various framework components, including rests, proximal plates, connectors, and clasp arms.
• AM-Cast frameworks showed larger lateral discrepancies in connectors, while SLS frameworks presented localized discrepancies in the lingual bar.

Conclusions:

• The accuracy of RPD frameworks fabricated by AM-Cast and SLS is component-dependent.
• Both digital fabrication methods present unique accuracy profiles that must be considered during framework design and manufacturing.
• Further research may be needed to optimize these techniques for improved RPD framework precision.