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Occlusal teeth surface accuracy of milled complete dentures: a comparison between different manufacturing techniques
Leonardo Ciocca1, Mattia Maltauro2, Volodymyr Kravets3
1Oral and Maxillo-Facial Prosthodontics, Section of Prosthodontics, Department of Biomedical and Neuromotor Science, Alma Mater Studiorum University of Bologna, Bologna, Italy.
The Journal of Advanced Prosthodontics
|September 8, 2025
Summary
The monolithic milling process offers superior accuracy for fabricating dentures compared to the oversize method. The Reference Point System (RPS) is a more reliable metrological tool for assessing digital dental manufacturing accuracy.
Area of Science:
- Digital dentistry
- Dental materials science
- CAD/CAM in prosthodontics
Background:
- Modern digital milling processes are increasingly used for fabricating dental prosthetics.
- Evaluating the occlusal trueness and precision of these processes is crucial for clinical success.
- Two distinct digital milling approaches, monolithic and oversize, are compared.
Purpose of the Study:
- To compare the occlusal trueness and precision of teeth manufactured using monolithic versus oversize digital milling processes.
- To evaluate the accuracy of two measurement methods: cusp area analysis and cusp vertex analysis.
- To assess under- and overcontouring inaccuracies associated with each milling process.
Main Methods:
- Thirty-eight complete dentures were fabricated using either a monolithic bicolor resin disk or the oversize process with two separate resin disks.
- Occlusal trueness and precision were evaluated using cusp area analysis and cusp vertex analysis.
- Statistical analyses included Welch's t-test, Wilcoxon signed-rank test, and modified signed-likelihood ratio test (SLRT).
Main Results:
- A statistically significant difference was found between the cusp vertex and cusp area analysis methods, with the vertex method showing greater accuracy (P < 2.2 × 10^-16).
- The monolithic process showed 55% overcontouring, while the oversize process exhibited 99% overcontouring, indicating greater surface roughness with the latter.
- The monolithic milling method demonstrated significantly higher accuracy than the oversize process (P < .05).
Conclusions:
- The monolithic milling method provides superior accuracy for complete denture fabrication compared to the oversize process.
- The Reference Point System (RPS) metrological method is more reliable than the best-fit method for evaluating complex structures in digital dentistry.
- Accurate assessment of trueness and precision is vital for optimizing digital manufacturing workflows in prosthodontics.
