Objectives: This study aimed to assess the efficacy of a digital manufacturing process including optical digitizing and 3-dimensional (3D) additive manufacturing for fabricating oral appliances (OAs) for obstructive sleep apnea. Fitness to dental arch and the retention force of OAs were compared between OAs manufactured using 3D printing with photopolymerizable resin and OAs manufactured using the conventional method with heat-polymerized acrylic resin.
Methods: Digitally manufactured OAs were made of photopolymerizable resin using a 3D printer (DWS DS 3000, DWS, Italy) based on the digital morphological data of the experimental dental cast (Nissin, Tokyo), which were optically obtained by TRIOS (3Shape, Denmark). As a control, OAs were manufactured using a heat-polymerized acrylic resin (Acron, GC, Tokyo) on a plaster dental cast made from the impression of the experimental dental cast (Nissin, Tokyo). OAs of the upper and lower arches in both groups (digital and conventional) were manufactured separately, and their inner surface fitness and retention force to the experimental dental cast were evaluated. The fitness of the OA was evaluated by assessing coincidence of the optically scanned images of the inner surface of the OA and the dental cast. Retention force was measured using a tensile test, in which the OA was worn on the experimental dental cast. To evaluate the influence of combining the upper and lower arches, the upper and lower arches of OAs separately manufactured were attached with acrylic resin on the articulator in both groups. Additionally, one-piece OAs were manufactured by 3D printing to merge the upper and lower parts on the software. The fitness of the OAs to the dental arches on the cast was compared among the three groups.
Results: The fitness of digitally manufactured OAs was significantly lower than that of the conventionally manufactured OAs. The retention force of the digitally manufactured OAs was significantly higher than that of the conventionally manufactured OAs. The fitness of one-piece OAs tended to be lower than that of OAs manufactured separately.
Conclusion: The results show that OAs manufactured using digital technology did not fit as accurately as conventionally made OAs. This could be the result of the polymerization shrinkage of photopolymerizable resin. Further development of the manufacturing processes and materials for digital fabrication of OAs is required.
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