Fracture Resistance of 3D-Printed Fixed Partial Dentures: Influence of Connector Size and Materials

Limited data are available regarding the mechanical performance of 3D-printed fixed partial dentures (FPDs) fabricated from different materials and connector geometries. The purpose of this in vitro study was to evaluate the influence of connector size and material type on the fracture resistance of three-unit posterior FPDs fabricated with two commercially available 3D-printable dental resins.

A standardized metal model with two cylindrical abutments was used to design three-unit FPDs. A total of sixty samples were produced, considering three connector sizes (3 × 3 mm, 4 × 4 mm, and 5 × 5 mm) and two different resins: Temp Print (GC Corp., Tokyo, Japan) and V-Print c&b temp (Voco GmbH, Cuxhaven, Germany) (n = 10). Specimens were fabricated with a DLP printer (Asiga MAX UV), post-processed per manufacturer recommendations, and tested for fracture resistance under occlusal loading using a universal testing machine. Data were analyzed using nonparametric tests (Mann-Whitney U and Kruskal-Wallis; α = 0.05).

Significant differences were found between material and connector size groups (p < 0.001). Temp Print (GC Corp., Tokyo, Japan) demonstrated higher mean fracture loads (792.34 ± 578.36 N) compared to V-Print c&b temp (Voco GmbH, Cuxhaven, Germany) (359.74 ± 131.64 N), with statistically significant differences at 4 × 4 and 5 × 5 mm connectors. Fracture strength proportionally increased with connector size. FPDs with 5 × 5 mm connectors showed the highest resistance, reaching values above 1500 N.

Both connector geometry and material composition significantly affected the fracture resistance of 3D-printed FPDs. Larger connector dimensions and the use of Temp Print (GC Corp., Tokyo, Japan) resin enhanced mechanical performance.