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Objectives: To compare the clinical performance of occlusal splints printed from thermo-flexible resin with milled splints.
Methods: A parallel two-arm pilot trial was initiated. Forty-seven patients (n women=38) were recruited from a tertiary care center and randomized using an online tool (sealed envelope). Inclusion criterion was an indication for treatment with a centric relation occlusal splint due to bruxism or any form of painful temporomandibular disorder. Patients were excluded if they were younger than 18 years, unable to attend follow-up appointments, or required another type of splint therapy. Patients received either, a 3D-printed (intervention group, V-print splint comfort, VOCO) or a milled splint (control group, ProArt CAD splint, Ivoclar). Construction software Ceramill M-splint (AmannGirrbach), 3D-printer MAX UV 385 (Asiga) and milling unit PrograMill PM7 (Ivoclar) were used. Follow-up assessments were conducted after 2 weeks and 3 months. Outcome measures were survival, adherence, technical complications, patient satisfaction on a 10-point Likert scale, and maximum wear using superimposition of optical scans.
Results: After 3 months, 20/23 intervention group and 18/24 control group participants were assessed. All splints survived. Minor complications were small crack formations on 6 printed and 4 milled splints. Mean patient satisfaction was 8 (SD 1.7) for printed, and 8.1 (SD 2.3) for milled splints (r = 0.1, p = .52). Median maximum wear was highly dispersed with 153 (IQR 140) in posterior and 195 (IQR 537) in frontal segments of printed, and 96 (IQR 78) respectively, 123 (IQR 155) of milled splints, (both: r = 0.31, p = .084).
Conclusions: Within the limitations of a pilot trial, 3D-printed and milled splints performed similarly in terms of patient satisfaction, complication rates and wear behavior.
Clinical Significance: Thermo-flexible material was proposed for 3D printing of occlusal splints to overcome mechanical weaknesses of previously available resins. This randomized pilot study provides evidence that this material is a viable alternative to milled splints for at least three months of clinical use. Further evidence on long-term use should be obtained.
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http://dx.doi.org/10.1016/j.jdent.2023.104514 | DOI Listing |
Dent J (Basel)
July 2025
Advanced Polymer Materials Group, National University of Science and Technology Politehnica Bucharest, 1-7 Gh. Polizu Street, 011061 Bucharest, Romania.
: Acrylic resin-based materials are a versatile category used extensively in various dental applications. Processed by current modern technologies, such as CAD/CAM technologies or 3D printing, these materials have revolutionized the field of dentistry for the efficient creation of dental devices. However, despite their extensive use, a limited number of comparative studies exist that investigate how different processing methods-such as traditional techniques, 3D printing, and CAD/CAM milling-impact the nano-mechanical behavior and internal porosity of these materials, which are critical for their long-term clinical performance.
View Article and Find Full Text PDFJ Prosthodont
July 2025
Department of Prosthodontics, Indiana University School of Dentistry, Indianapolis, Indiana, USA.
Purpose: To evaluate the impact of different complete-arch digital scanning techniques and prosthesis types on the passive fit of computer-aided design and computer-aided manufacturing (CAD-CAM) verification devices.
Materials And Methods: Two different maxillary master casts with four multi-unit abutment (MUA) implant analogs (FP-1 and FP-3 prosthesis types) were used as the basis for fabricating verification devices through two impression techniques (OptiSplint and RevEX). Group 1 utilized digital scans of splinted scanbodies reinforced with a light-polymerizing acrylic resin and metal mesh on the FP-1 cast (OptiSplint technique), Group 2 employed the same impression technique as Group 1 on the FP-3 cast, Group 3 applied digital scans of reverse scanbodies connected to a passively fitting interim prosthesis on FP-1 cast (RevEX technique), and Group 4 used the same impression technique as Group 3 on FP-3 cast.
J Prosthodont
August 2025
Department of Prosthodontics, Indiana University School of Dentistry, Indianapolis, Indiana, USA.
Purpose: To evaluate the impact of different complete-arch digital scanning techniques on the passive fit of computer-aided design and computer-aided manufacturing (CAD-CAM) verification devices.
Materials And Methods: A mandibular master cast with four multiunit abutment implant analogs was used as the basis for fabricating verification devices through three impression techniques. Group 1 employed a conventional open-tray impression technique using polyvinyl siloxane material, Group 2 utilized digital scans of splinted scanbodies reinforced with a light-polymerizing acrylic resin and metal mesh, and Group 3 applied digital scans of reverse scanbodies connected to a passively fitting interim prosthesis.
3D Print Med
June 2025
VCU Dental Building #1, 521 North 11 Street 3rd Floor, Room 315 BOX 980566, Richmond, VA, 23298-05666, USA.
Background: Both outsourcing virtual surgery planning and 3D printed splint fabrication have become the standard in the field of orthognathic surgery. In-house (IH) adaptation of these presurgical operations requires compliance with regulatory bodies when designing and manufacturing medical-grade products. The purpose of this study is to evaluate the dimensional accuracy of IH 3D printed orthognathic surgical splints within a hybrid workflow for externally designed splints.
View Article and Find Full Text PDFJ Prosthet Dent
September 2025
Affiliate Professor, Graduate Prosthodontics, Department of Restorative Dentistry, School of Dentistry, University of Washington, Seattle, Wash.; Faculty and Director, Research and Digital Dentistry, Kois Center, Seattle, Wash; and Affiliate Professor, Graduate Prosthodontics, Department of Prosthod
Statement Of Problem: Digital scans for complete arch implant fixed dental prostheses are typically performed using implant scan bodies (ISBs). Scannable healing abutments may be an alternative to ISBs. However, evidence on the accuracy, scanning time, and number of photograms of digital scans using scannable healing abutments remains uncertain.
View Article and Find Full Text PDF