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3D printing vs. conventional wax patterns: a comparative in vitro study on retention of RPD framework.

Asim Elsir Elmahdi1, Saurabh Chaturvedi1, Mohamed Khaled Addas1

  • 1Department of Prosthetic Dentistry, College of Dentistry, King Khalid University, 62529, Abha, Saudi Arabia.

Odontology
|March 17, 2026
PubMed
Summary

3D-printed removable partial denture (RPD) frameworks show significantly better retention than traditional wax patterns. This digital dentistry advancement improves RPD fit and patient satisfaction in prosthodontic rehabilitation.

Keywords:
3D printingDigital dentistryDigital workflowKennedy’s classificationRPDRetention

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Area of Science:

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

Background:

  • Removable partial dentures (RPDs) are crucial for prosthodontic rehabilitation, with retention directly impacting function and patient satisfaction.
  • Conventional wax-up fabrication methods for RPD frameworks are susceptible to manual errors, potentially compromising fit and retention.
  • Digital dentistry innovations, including 3D printing, offer promising alternatives for fabricating RPD frameworks with enhanced precision.

Purpose of the Study:

  • To compare the retention of cobalt-chromium RPD frameworks fabricated using conventional wax patterns versus 3D-printed castable resin patterns.
  • To evaluate the impact of digital fabrication techniques on the retentive properties of RPD frameworks.
  • To assess the potential of 3D printing to improve clinical outcomes in removable prosthodontics.

Main Methods:

  • An in vitro experimental study utilizing prefabricated typodont models (mandibular Kennedy Class I, maxillary Kennedy Class II mod 2).
  • Fabrication of 120 RPD frameworks (60 per arch) divided into conventional (wax) and 3D-printed castable resin groups.
  • Measurement of framework retention using an electronic vertical pull device, followed by statistical analysis (paired t tests, Wilcoxon signed-rank tests).

Main Results:

  • 3D-printed RPD frameworks exhibited significantly higher retention than conventional wax-pattern frameworks for both mandibular (4.82 N vs. 3.86 N) and maxillary arches (49.67 N vs. 40.92 N).
  • Statistical analysis confirmed a significant difference in retention favoring the 3D-printed group (p < 0.001 for both arches).
  • Effect sizes indicated a substantial difference in retention between the fabrication methods.

Conclusions:

  • RPD frameworks fabricated using 3D-printed castable resin patterns demonstrate superior retention compared to those made with conventional wax patterns.
  • The findings support the integration of digital workflows and 3D printing technology in removable prosthodontics.
  • 3D printing holds potential for enhancing the clinical performance and patient outcomes of removable partial dentures.