Effect of layer thickness, build angle, and viscosity on the mechanical properties and manufacturing trueness of denture base resin for digital light processing

Digital light processing 3D printing of flexible devices: actuators, sensors and energy devices

Flexible devices are increasingly crucial in various aspects of our lives, including healthcare devices and human-machine interface systems, revolutionizing human life. As technology evolves rapidly, there is a high demand for innovative manufacturing methods that enable rapid prototyping of custom and multifunctional flexible devices with high quality. Recently, digital light processing (DLP) 3D printing has emerged as a promising manufacturing approach due to its capabilities of creating intricate customized structures, high fabrication speed, low-cost technology and widespread adoption. This review provides a state-of-the-art overview of the recent advances in the creation of flexible devices using DLP printing, with a focus on soft actuators, flexible sensors and flexible energy devices. We emphasize how DLP printing and the development of DLP printable materials enhance the structural design, sensitivity, mechanical performance, and overall functionality of these devices. Finally, we discuss the challenges and perspectives associated with DLP-printed flexible devices. We anticipate that the continued advancements in DLP printing will foster the development of smarter flexible devices, shortening the design-to-manufacturing cycles.

Flexural Strength and Surface Properties of 3D-Printed Denture Base Resins-Effect of Build Angle, Layer Thickness and Aging

A variety of printable resins for denture bases are available, without detailed instructions on print parameters. This study aimed to evaluate the effect of the printing build angle and the layer thickness of 3D-printed denture base resins before and after thermocyclic aging on flexural strength values and surface properties. The flexural strength, surface roughness (Ra, Rz) and hardness (HM, HV2) of two 3D-printed denture base resins (Formlabs (FL) and V-print dentbase, VOCO, (VC)) were therefore compared to a conventionally pressed cold-curing control material (PalaXpress (PP)). The specimens were printed at a 0°, 45° or 90° build angle and the layer thickness was varied for FL at 50 and 100 µm and evaluated before and after thermocyclic aging (N = 200; n = 10). Differences in flexural strength values were analyzed using multifactorial ANOVAs (α = 0.05). The build angle and aging significantly affected the flexural strength of the 3D-printed denture base resins (p < 0.05), while the layer thickness showed no effect for FL (p = 0.461). The required threshold value of 65 MPa defined by ISO 20795-1 was exceeded by PP (70.5 MPa ± 5.5 MPa), by FL when printed at 90° (69.3 MPa ± 7.7 MPa) and by VC at 0° (69.0 MPa ± 4.6 MPa). The choice of an appropriate build angle for each material and printing technology is crucial for the flexural strength and consequently the clinical longevity of a printed denture base.

Effect of coffee thermal cycling on the surface properties and stainability of additively manufactured denture base resins in different layer thicknesses

PURPOSE

To compare the effect of coffee thermal cycling on surface roughness (Ra), Vickers microhardness (MH), and stainability of denture base resins additively manufactured in different layer thicknesses with those of subtractively manufactured denture base materials.

MATERIALS AND METHODS

Eighty disk-shaped specimens (Ø10×2 mm) were fabricated from two subtractively (Merz M-PM [SM-M] and G-CAM [SM-G]) and three additively (NextDent 3D+ [50 µm, AM-N-50; 100 µm, AM-N-100], FREEPRINT Denture [50 µm, AM-F-50; 100 µm, AM-F-100], and Denturetec [50 µm, AM-S-50; 100 µm, AM-S-100]) manufactured denture base materials (n = 10). Ra measurements were performed before and after polishing by using a non-contact optical profilometer, while MH values and color coordinates were measured after polishing. Specimens were then subjected to 5000 cycles of coffee thermal cycling, all measurements were repeated, and color differences (ΔE00) were calculated. A linear mixed effect model was used to analyze Ra and MH data, while one-way analysis of variance was used to analyze ΔE00 data (α = 0.05). Ra values were further evaluated according to a clinically acceptable threshold of 0.2 µm, while ΔE00 values were evaluated according to perceptibility (1.72 units) and acceptability (4.08 units) thresholds. The interaction between the material type and the time interval affected both Ra and MH (p ≤ 0.001). Tested materials had their highest Ra before polishing (p ≤ 0.029). Before polishing, AM-F-100 had the highest, and SM-M and SM-G had the lowest Ra (p < 0.001). After polishing and after coffee thermal cycling, SM-G mostly had lower Ra than those of other materials (p ≤ 0.036). SM-G mostly had higher MH than that of other materials before and after coffee thermal cycling (p ≤ 0.025). Coffee thermal cycling reduced the MH of SM-M and increased that of AM-S-100 (p ≤ 0.024). AM-N-100 had higher ΔE00 than AM-F, AM-S-100, and SM-G (p ≤ 0.009), while AM-F and SM-G had lower ΔE00 than AM-S-50 and AM-N-50 (p ≤ 0.024).

CONCLUSIONS

Polishing reduced the surface roughness of all materials, whereas the effect of coffee thermal cycling was nonsignificant. Most of the tested materials had acceptable surface roughness after polishing and after coffee thermal cycling according to the reported threshold. Layer thickness only affected the microhardness of tested additively manufactured resins, which was material-dependent. Subtractively manufactured specimens mostly had high microhardness and that of nonreinforced subtractively manufactured resin decreased after coffee thermal cycling. When reported color thresholds are considered, all materials had acceptable color stability.

Four Different Build Angles in 3D-Printed Complete Denture Bases: A Comparative In Vitro Study

In this study, we aimed to investigate the differences in tissue surface adaptation and the variations in distances between reference points on the polished surfaces of 3D-printed denture bases produced at different build angles. The build angles were 0°, 30°, 60°, and 90°, with 15 denture bases printed for each angle. Using the Geomagic Control® software, a 3D best-fit alignment was conducted between the denture base tissue surface and the reference shape of the edentulous maxilla model to calculate the root mean square error. The distances between reference points on the polished surface were measured using digital calipers. A one-way analysis of variance was conducted for statistical analysis. The adaptation, as measured by the root mean square error, varied significantly among denture bases with different build angles. The distances between the anterior and posterior reference points of the polished surface were also significantly different. However, within the limitations of this study, the variations in adaptations and dimensional accuracy across different build angles were within clinically acceptable ranges. In clinical practice, the print angle can be adjusted based on factors such as printing time, resin consumption, and the number of denture bases being printed simultaneously.

Impact of Printing Orientation on the Accuracy of Additively Fabricated Denture Base Materials: A Systematic Review

Printing orientation is one of the printing parameters that affect the properties of three-dimensional (3D)-printed resins. Different printing orientations and directions have been suggested; however, no clear and specific orientations are recommended in the literature in terms of the printing orientation effect on the accuracy and fit of 3D-printed removable dental prostheses. This review aimed to evaluate the effect of printing orientation on the fit and accuracy of 3D-printed removable dental prostheses. The PubMed, Scopus, and Web of Science databases were searched for published articles that investigated the effect of printing orientations on the accuracy and fit of the 3D-printed denture base. Full-length English published articles were searched between January 2010 and December 2023, which examined topics related to printing orientations, building angles, 3D printing, printing technology, accuracy, dimensional changes, internal fit, marginal integrity, marginal discrepancies, trueness, precision, and adaptation. Of the ten included studies, one investigated maxillary and mandibular denture bases, seven assessed maxillary denture bases, and two evaluated mandibular bases. Different printing orientations, ranging from 0° to 315°, were explored, with a higher prevalence of 0°, 45°, and 90°. The included studies utilized stereolithography and digital light processing printing technologies. High accuracy was observed at 45°, followed by 90. Additional struts and bars on the cameo surface increased the accuracy of the 3D-printed denture base. These results shows that printing orientation has a significant effect on the accuracy of 3D-printed resin, with 45° exhibiting the highest accuracy. In addition to the support structure, the density and position can impact the accuracy.

Effect of layer thickness and polishing on wear resistance of additively manufactured occlusal splints

OBJECTIVE

To evaluate the effect of polishing and layering thickness on the wear resistance of 3D-printed occlusal splint materials.

METHODS

Specimens with 3 different layer thicknesses (50, 75, 100 µm) were produced in the form of a disc 3 mm thick using V-Print splint resin on a 3D-printer with digital light processing technology. (n = 16 for each thickness) All specimens were washed and cured according to the manufacturer's instructions. Half of the specimens of each layer thickness were polished with silicon carbide papers. All specimens were subjected to 120.000 cycles of a chewing simulator for 2-body wear tests. Before and after the wear test, the specimens were scanned with a laser scanner, and the images were overlaid using a 3D analysis program and the volume loss was calculated. The wear patterns of the specimens were examined under a scanning electron microscope. Statistical evaluation was performed using a Shapiro-Wilk test, 2-way ANOVA, 1-way ANOVA, and Tukey post hoc test (α = 0.05).

RESULTS

While polishing had a significant effect (p = 0.003) on the wear volume of the occlusal splints, layer thickness (p = 0.105) and their interaction between polishing and layer thickness (p = 0.620) did not significantly affect the wear volume. Regardless of the polishing, the lowest mean wear was observed for D50 (0.064 mm3), followed by D75 (0.078 mm3), and D100 (0.096 mm3). However, a significant difference was observed only between polished D50 and unpolished D100.

CONCLUSION

The polished 3D-printed occlusal splint resin showed higher wear resistance than the unpolished one, regardless of the layer thickness.

CLINICAL SIGNIFICANCE

Since different layer thicknesses of 50 µm and greater had no effect on the wear resistance of the material, a layer thickness of 100 µm may be preferred for faster printing. However, polishing occlusal splints may reduce the amount of wear and improve clinical performance.

Antimicrobial activity, surface properties, and cytotoxicity of microencapsulated phytochemicals incorporated into three-dimensionally printable dental polymers

OBJECTIVES

This study aimed to investigate the antimicrobial properties of three dimensionally-printed dental polymers (3DPs) incorporated with microencapsulated phytochemicals (MPs) and to assess their surface characteristics and cytotoxicity.

METHODS

MPs derived from phytoncide oil and their specific chemical components were introduced into suspensions of three microbial species: Streptococcus gordonii, Streptococcus oralis, and Candida albicans. Optical density was measured to determine the microbial growth in the presence of MPs for testing their antimicrobial activity. MPs at 5% (w/w) were mixed with dental polymers and dispersants to 3DP discs. These microbial species were then seeded onto the discs and incubated for 24 h. The antibacterial and antifungal activities of MP-containing 3DPs were evaluated by counting the colony-forming units (n = 3). The biofilm formation on the 3DP was assessed by crystal violet staining assay (n = 3). Microbial viability was determined using a live-dead staining and CLSM observation (n = 3). Surface roughness and water contact angle were assessed (n = 10). Cytotoxicity of MP-containing 3DPs for human gingival fibroblast was evaluated by MTT assay.

RESULTS

MPs, particularly (-)-α-pinene, suppressed the growth of all tested microbial species. MP-containing 3DPs significantly reduced the colony count (P ≤ 0.001) and biofilm formation (P ≤ 0.009), of all tested microbial species. Both surface roughness (P < 0.001) and water contact angle (P < 0.001) increased. The cytotoxicity remained unchanged after incorporating MPs to the 3DPs (P = 0.310).

CONCLUSIONS

MPs effectively controlled the microbial growth on 3DPs as evidenced by the colony count, biofilm formation, and cell viability. Although MPs modified the surface characteristics, they did not influence the cytotoxicity of 3DPs.

CLINICAL SIGNIFICANCE

Integration of MPs into 3DPs could produce dental prostheses or appliances with antimicrobial properties. This approach not only provides a proactive solution to reduce the risk of oral biofilm-related infection but also ensures the safety and biocompatibility of the material, thereby improving dental care.