Physical–mechanical properties and accuracy of additively manufactured resin denture bases: Impact of printing orientation

Abstract

Purpose: This systematic review evaluated the effect of different printing orientations on the physical-mechanical properties and accuracy of resin denture bases and related specimens.

Study selection: Utilizing PRISMA 2020 guidelines, a comprehensive search of PubMed, Web of Science, Cochrane, and Scopus databases was conducted until June 2024. Included studies examined the accuracy, volumetric changes, and mechanical or physical properties of 3D-printed denture bases in various orientations. Studies without relevant data were excluded. Bias risk was assessed using a modified CONSORT checklist.

Results: This review included 24 studies on 3D-printed denture base resins, mainly based on stereolithography and digital light processing. Horizontal orientation (0°) generally enhanced flexural strength, while tilted and vertical orientations (90°) reduced it. Microhardness results varied due to differences in materials, layer thicknesses, and post-curing. Surface roughness was highest at 45°. Vertical orientation uses less material but is less time-efficient. Microbial adhesion, influenced by surface roughness, varied with printing orientation without a clear consensus on the optimal direction.

Conclusions: Printing orientation significantly impacts the physical and mechanical properties and accuracy of 3D-printed resin dentures. A horizontal orientation (0°) improved flexural strength, while accuracy and adaptability were better at 45° and 90°. Surface roughness, translucency, and chemical stability are also affected by orientation, post-curing, and material choice. Although a 90° orientation reduces material use, it increases printing time. Standardized study designs are recommended for drawing definitive conclusions in future research.