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Three-Dimensionally Printed Splints in Dentistry: A Comprehensive Review.

Luka Šimunović¹, Samir Čimić², Senka Meštrović¹

¹Department of Orthodontics, School of Dental Medicine, University of Zagreb, 10000 Zagreb, Croatia.

Dentistry Journal

|July 25, 2025

Summary

Three-dimensional (3D) printing offers customizable dental splints with faster production. However, 3D-printed splints show lower mechanical strength than traditional materials, requiring further research for long-term durability.

Keywords:

DLP SLA additive manufacturing biocompatibility digital workflow occlusal devices orthodontics resin materials temporomandibular disorder

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Area of Science:

Dental Materials Science
Biomedical Engineering
Additive Manufacturing

Background:

Three-dimensional (3D) printing is revolutionizing dental splint fabrication.
It offers enhanced customization, speed, material efficiency, and patient comfort.

Purpose of the Study:

To review the clinical use, benefits, limitations, and future of 3D-printed dental splints.
To discuss 3D printing technologies and photopolymer resins for splint fabrication.

Main Methods:

Literature synthesis of current research on 3D-printed dental splints.
Discussion of stereolithography (SLA), digital light processing (DLP), and material jetting.
Analysis of photopolymer resin properties and mechanical performance.

Main Results:

3D-printed splints generally meet ISO standards but exhibit 15-30% lower flexural strength than PMMA.
High variability in mechanical properties (flexural strength 50-100 MPa) and reduced hardness/fatigue resistance noted in some resins.
Clinical applications include occlusal stabilization, surgical wafers, orthodontic retainers, and endodontic guides.

Conclusions:

3D printing is a versatile tool for dental splint therapy, despite current limitations.
Limitations include material aging, post-processing, and outcome variability.
Future innovations and research into long-term durability and quality control are crucial for broader adoption.