Clinical Performance of High-Impact 3D-Printed Denture Resins: A Multicenter Cohort With Survival Analysis

Background The clinical performance of 3D-printed denture base resins remains incompletely defined under real-world conditions, where workflow variability may influence outcomes beyond material properties alone. Objective This study aimed to compare the clinical performance of Lucitone Digital Print (LDP) (Dentsply Sirona, Charlotte, NC, USA) and SprintRay High Impact (SRHI) (SprintRay, Los Angeles, CA, USA) 3D-printed dentures in a multicenter cohort. The primary objective was to evaluate functional retention in vivo. Secondary objectives included comparison of fracture-free survival, fracture incidence, time to fracture, failure etiology, and assessment of workflow-related factors that may influence clinical outcomes independent of material properties. Methods A cohort of 1,011 dentures (510 LDP, 501 SRHI) was followed through December 31, 2025. Functional retention in vivo was the primary endpoint. Kaplan-Meier survival analysis, log-rank testing, and Cox proportional hazards modeling were performed. Secondary outcomes included fracture-free survival, cumulative breakage rates, time to fracture, and root cause analysis. Results At the final follow-up, 68.0% of LDP and 52.3% of SRHI units remained in vivo. SRHI demonstrated significantly greater functional discontinuation (HR: 1.79; 95% CI: 1.47-2.18; P<.001). Fracture rates were similar between groups (13.3% vs 12.6%), and fracture-free survival did not differ significantly (P=.340). Failures were predominantly associated with prosthesis design and workflow variables. Conclusion Clinical outcomes of 3D-printed dentures are driven more by workflow execution and prosthesis design than by material selection alone.