Advances in 3D Printing for Removable Prosthetics-Insights and Perspectives

This review summarizes recent advances in three-dimensional (3D) printing for removable prosthodontics, including complete dentures, removable partial dentures, implant-retained overdentures, and occlusal splints. The aim is to provide clinicians with an overview of current technologies, clinical performance, and future perspectives.

While subtractive methods are well established, additive manufacturing has recently gained exponential importance, especially in removable restorations. Vat-photopolymerization resins are widely applied for denture bases, teeth, and occlusal splints, while laser sintering enables fabrication of metal frameworks and implant attachments with high accuracy. Clinical studies indicate that printed complete dentures achieve outcomes in adaptation and patient satisfaction comparable to conventional or milled prostheses, with reduced appointment numbers and digital reproducibility. Removable partial denture frameworks and implant-overdenture attachments fabricated by selective laser melting demonstrate promising accuracy and mechanical properties, though process variability and post-processing remain critical aspects. Printed occlusal splints are widely adopted and offer adequate fit and comfort, though material-related challenges and limited long-term data are concerns.

3D printing emerges as a reliable option for removable dentures, frameworks, and occlusal devices. Future developments in multi-material printing, durable and bioactive resins, and standardized clinical protocols will further define its role in prosthodontics.

3D printing is transforming removable prosthodontics. Clinicians can already benefit from streamlined workflows, a standardized process chain, reduced treatment time, and the ability to reproduce dentures, while patients gain from improved comfort and fewer visits. Awareness of material limitations and processing-related specifics remains essential for long-term success. Looking ahead, multi-material printing-allowing simultaneous fabrication of denture bases, teeth, and maybe frameworks-holds promise for improving structural integrity, esthetics, and overall clinical efficiency.