Effects of layer thickness and build angle on the microbial adhesion of denture base polymers manufactured by digital light processing

The Effect of Manufacturing Factors on the Material Properties and Adhesion of C. albicans and S. mutans on Additive Denture Base Material

(1) Understanding the effects of manufacturing factors on microbial adhesion is essential for optimizing additive denture base materials and improving their clinical performance. This study evaluated how polymerization time, layer thickness, extended cleaning, and storage conditions influence C. albicans and S. mutans adhesion on a denture base material. (2) Specimens (n = 15/group, d = 8 mm, h = 2 mm) were additively fabricated or poured (reference). Digital light processing was performed with varying polymerization times, layer thicknesses, extended cleaning, and storage. Microbial adhesion was assessed using a luminescence assay. Surface properties were characterized by roughness (Sa/Sz), hardness, and surface free energy (SFE). Statistics: The Shapiro-Wilk test, ANOVA, Bonferroni post hoc test, and Pearson correlation (α = 0.05) were utilized. (3) Polymerization time, layer thickness, cleaning, and storage conditions significantly influenced C. albicans and S. mutans adhesion. Increased layer thickness reduced C. albicans adhesion but promoted S. mutans colonization, emphasizing the role of SFE. Extended polymerization and optimized cleaning reduced microbial adhesion, highlighting the need for tailored processing to enhance microbial resistance and material integrity. (4) Manufacturing factors influenced microbial adhesion, with additive materials reducing the abundance of C. albicans but increasing the abundance of S. mutans, underscoring the importance of material adjustments and extended polymerization to enhance microbial resistance.

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.

Shear bond strength of ultraviolet-polymerized resin to 3D-printed denture materials: Effects of post-polymerization, surface treatments, and thermocycling

PURPOSE

The purpose of this study is to compare the shear bond strength of ultraviolet (UV)-polymerized resin to 3D-printed denture materials, both with and without post-polymerization. Moreover, the effects of surface treatment and thermocycling on shear bond strength after post-polymerization were investigated.

METHODS

Cylindrical 3D-printed denture bases and teeth specimens were prepared. The specimens are subjected to two tests. For Test 1, the specimens were bonded without any surface treatment or thermal stress for comparison with and without post-polymerization. In Test 2, specimens underwent five surface treatments: untreated (CON), ethyl acetate (EA), airborne particle abrasion (APA) with 50 μm (50-APA) and 110 μm alumina (110-APA), and tribochemical silica coating (TSC). A UV-polymerized resin was used for bonding. Half of the Test 2 specimens were thermocycled for 10,000 cycles. Shear bond strength was measured and analyzed using Kruskal-Wallis and Steel-Dwass tests (n = 8).

RESULTS

In Test 1, post-polymerization significantly reduced shear bond strength of both 3D-printed denture materials (P < 0.05). No notable difference was observed between the denture teeth and the bases (P > 0.05). In Test 2, before thermocycling, the CON and EA groups exhibited low bond strengths, while the 50-APA, 110-APA, and TSC groups exhibited higher bond strengths. Thermocycling did not reduce bond strength in the latter groups, but significantly reduced bond strength in the EA group (P < 0.001).

CONCLUSIONS

Post-polymerization can significantly reduce the shear bond strength of 3D-printed denture materials. Surface treatments, particularly APA and TSC, maintained bond strength even after thermocycling.

Surface characteristics, cytotoxicity, and microbial adhesion of 3D-printed hybrid resin-ceramic materials for definitive restoration

OBJECTIVE

This study investigated the surface properties, cytotoxicity, and microbial adhesion of 3D-printed specimens made from hybrid resin-ceramic materials intended for use in definitive crowns.

METHODS

Disc-shaped specimens were 3D-printed using six different hybrid resin-ceramic materials recommended for definitive restorations: Crowntec (CT), VarseoSmile Crown Plus (VS), Tera Harz TC-80DP Graphy (TH), C&B Permanent ODS (CB), Formlabs Permanent Crown (FP), and HeyGears (HG). Surface topography, surface roughness, and water contact angle values were measured for each material (n = 6). Cytotoxicity was assessed using direct contact and extract tests on human gingival fibroblasts (n = 4). Additionally, the adhesion of mixed oral bacteria to the surfaces of the specimens was evaluated by counting colony-forming units (CFUs) after a 2-hour incubation period (n = 6).

RESULTS

The TH group exhibited significantly lower surface roughness (Ra: 0.28 ± 0.13 μm) compared to the other materials (CT: 1.87 ± 0.34 μm; VS: 1.13 ± 0.09 μm; CB: 2.91 ± 0.27 μm; FP: 2.50 ± 0.08 μm; HG: 1.50 ± 0.55 μm). The VS group had the highest water contact angle (129.5 ± 1.1°), indicating greater hydrophobicity, in contrast to the other groups (CT: 72.6 ± 2.1°; TH: 75.0 ± 0.3°; CB: 69.1 ± 0.2°; FP: 93.0 ± 1.6°; HG: 77.7 ± 0.3°). Cytotoxicity testing showed no harmful effects, as relative cell viability exceeded 70 %, and lactate dehydrogenase (LDH) release remained below 30 % for all materials. The TH specimens also demonstrated the lowest bacterial adhesion.

CONCLUSIONS

The surface characteristics of the tested resin-ceramic materials varied significantly, with TH showing the smoothest surface and the least bacterial adhesion. All materials were found to be non-toxic. Therefore, TH material has the potential to provide definitive restorations with less microbial adhesion.

CLINICAL SIGNIFICANCE

The type of resin-ceramic material significantly affects the surface properties of 3D-printed specimens. These findings are crucial for selecting the appropriate resin-ceramic material for definitive restorations.

Zirconia crowns manufactured using digital light processing: Effects of build angle and layer thickness on the accuracy

OBJECTIVES

This study investigated the effects of build angle and layer thickness on the trueness and precision of zirconia crowns manufactured using digital light processing (DLP) technology.

MATERIALS AND METHODS

Single crowns were fabricated from zirconia using DLP technology. The crowns were manufactured with three different representative build angles (0°, 45°, and 90°) and two different layer thicknesses (30 μm and 50 μm). After printing, the specimens were non-contact-scanned, and their accuracy was assessed using a 3D analysis software. Root mean square (RMS) values were used to determine trueness and precision. Color maps were generated to detect deviations within the specimens. Statistical analyses were conducted using two-way ANOVA.

RESULTS

Build angle and layer thickness significantly affected trueness and precision (p < 0.05). At a 30-μm layer thickness, the crowns printed at angles of 0° (32.2 ± 3.2 μm) and 45° (33.9 ± 2.4 μm) demonstrated the best marginal trueness compared to those in other groups (p < 0.05). Notably, those printed at an angle of 90° exhibited the best intaglio surface trueness (37.4 ± 4.0 μm). At a 50-μm layer thickness, the crowns printed at an angle of 90° exhibited the lowest accuracy concerning marginal and intaglio surface aspects (27.7 ± 8.2 μm).

CONCLUSIONS

Both the build angle and layer thickness significantly affected the dimensional accuracy of DLP-printed zirconia crowns, with the 30-μm layer thickness offering superior trueness. Optimal results were achieved using build angles of 0° and 45° in conjunction with thinner layers, minimizing marginal defects.

CLINICAL SIGNIFICANCE

All zirconia crowns produced at different build angles and layer thicknesses satisfied clinical requirements. Specific combinations of these factors realized the fabrication of single crowns that possessed the highest accuracy.

Investigation of adhesion status of Candida species to the surface of resin materials produced at different angles with additive manufacturing

BACKGROUND

The aim of this study was to evaluate the adhesion of Candida glabrata, Candida albicans, Candida krusei, Candida parapsilosis and Candida tropicalis yeasts to disk-shaped resin materials produced from resin which used in the production of surgical guide with 0, 45 and 90-degrees printing orientations by Liquid Crystal Display additive manufacturing technology.

METHODS

Disk-shaped specimens were printed with surgical guide resin using the Liquid Crystal Display production technique in 3 printing orientations (0, 45 and 90-degrees). Surface roughness and contact angle values were evaluated. Real-Time PCR analysis was performed to evaluate Candida adhesion (C. glabrata, C. albicans, C. krusei, C. parapsilosis and C. tropicalis) Field emission scanning electron microscope (FESEM) images of the materials were obtained.

RESULTS

Specimens oriented at 45-degrees demonstrated higher surface roughness (P < .05) and lower contact angle values than other groups. No significant difference was found in the adhesion of C. glabrata, C. albicans, and C. parapsilosis among specimens printed at 0, 45, and 90-degrees orientations (P > .05). A higher proportion of C. krusei and C. tropicalis was found in the specimens printed at orientation degrees of 45 = 90 < 0 with statistical significance. Analyzing the adhesion of all Candida species reveals no statistical disparity among the printing orientations.

CONCLUSIONS

The surface roughness, contact angle, and adhesion of certain Candida species are affected by printing orientations. Hence, careful consideration of the printing orientation is crucial for fabricating products with desirable properties. In 45-degree production, roughness increases due to the layered production forming steps, whereas in 0-degree production, certain Candida species exhibit high adhesion due to the formation of porous structures. Consequently, considering these factors, it is advisable to opt for production at 90-degrees, while also considering other anticipated characteristics.

Tendency of microbial adhesion to denture base resins: a systematic review

Objectives

Digital denture fabrication became an alternative method to conventional denture fabrication. However reviewing the antimicrobial performance of newly introduced digital fabrication methods in comparison to the conventional method is neglected. Aim of study: this review was to compare the antiadherence properties of various CAD-CAM subtractive (milled), additive (3D printed) conventional denture base resins. In order to answer the developed PICO question: "Does CAD-CAM milled and 3D printed denture base resins have microbiological antiadherence properties over the conventional ones?" We included comparative studies on digitally fabricated Denture base resins with conventionally fabricated one in term of microbial adhesion.

Methods

All in vitro studies investigated the microbial adherence to CAD-CAM milled and 3D printed denture base resins in comparison to conventional were searched in the PubMed, Web of Sciences, and Scopus databases up to December 2023.

Results

Fifteen studies have been investigated the microbial adhesion to milled and 3D printed denture base resins. CAD-CAM milled resins significantly decreased the microbial adhesion when compared with the conventional resins and 3D printed resins, while the later showed a high tendency for microbial adhesion. The addition of antifungal agents to 3D printed resins significantly reduced C. albicans adhesion. In terms of 3D printing parameters, printing orientation affected adherence while printing technology had no effect on microbial adhesion.

Conclusion

Denture base materials and fabrication methods significantly affect the microbial adhesion. CAD-CAM milled denture base resins demonstrated low microbial adhesion. 3D-printed resins showed high tendency for C. albicans adhesion. The antiadherent properties of 3D-printed resins can be improved by incorporating antifungal agents or changing the printing parameters, but further investigations are required to validate these modifications.

Evaluation of surface roughness, wettability and adhesion of multispecies biofilm on 3D-printed resins for the base and teeth of complete dentures

OBJECTIVE

This study evaluated the surface roughness, wettability and adhesion of multispecies biofilms (Candida albicans, Staphylococcus aureus and Streptococcus mutans) on 3D-printed resins for complete denture bases and teeth compared to conventional resins (heat-polymerized acrylic resin; artificial pre-fabricated teeth).

METHODOLOGY

Circular specimens (n=39; 6.0 mm Ø × 2.0 mm) of each group were subjected to roughness (n=30), wettability (n=30) and biofilm adhesion (n=9) tests. Three roughness measurements were taken by laser confocal microscopy and a mean value was calculated. Wettability was evaluated by the contact angle of sessile drop method, considering the mean of the three evaluations per specimen. In parallel, microorganism adhesion to resin surfaces was evaluated using a multispecies biofilm model. Microbial load was evaluated by determining the number of Colony Forming Units (CFU/mL) and by scanning electron microscopy (SEM). Data were subjected to the Wald test in a generalized linear model with multiple comparisons and Bonferroni adjustment, as well as two-way ANOVA (α=5%).

RESULTS

The roughness of the conventional base resin (0.01±0.04) was lower than that of the conventional tooth (0.14±0.04) (p=0.023) and 3D-printed base (0.18±0.08) (p<0.001). For wettability, conventional resin (84.20±5.57) showed a higher contact angle than the 3D-printed resin (60.58±6.18) (p<0.001). Higher microbial loads of S. mutans (p=0.023) and S. aureus (p=0.010) were observed on the surface of the conventional resin (S. mutans: 5.48±1.55; S. aureus: 7.01±0.57) compared to the 3D-printed resin (S. mutans: 4.11±1.96; S. aureus: 6.42±0.78). The adhesion of C. albicans was not affected by surface characteristics. The conventional base resin showed less roughness than the conventional dental resin and the printed base resin.

CONCLUSION

The 3D-printed resins for base and tooth showed less hydrophobicity and less adhesion of S. mutans and S. aureus than conventional resins.

Microbial adhesion and biofilm formation by Candida albicans on 3D-printed denture base resins

This study evaluated surface properties and adhesion/biofilm formation by Candida albicans on 3D printed denture base resins used in 3D printing. Disc-shaped specimens (15 mm x 3 mm) of two 3D-printed resins (NextDent Denture 3D+, NE, n = 64; and Cosmos Denture, CO, n = 64) and a heat-polymerized resin (Lucitone 550, LU, control, n = 64) were analyzed for surface roughness (Ra μm) and surface free energy (erg cm-2). Microbiologic assays (90-min adhesion and 48-h biofilm formation by C. albicans) were performed five times in triplicate, with the evaluation of the specimens' surface for: (i) colony forming units count (CFU/mL), (ii) cellular metabolism (XTT assay), and (iii) fluorescence and thickness of biofilm layers (confocal laser scanning microscopy). Data were analyzed using parametric and nonparametric tests (α = 0.05). LU presented higher surface roughness Ra (0.329±0.076 μm) than NE (0.295±0.056 μm) (p = 0.024), but both were similar to CO (0.315±0.058 μm) (p = 1.000 and p = 0.129, respectively). LU showed lower surface free energy (47.47±2.01 erg cm-2) than CO (49.61±1.88 erg cm-2) and NE (49.23±2.16 erg cm-2) (p<0.001 for both). The CO and NE resins showed greater cellular metabolism (p<0.001) and CO only, showed greater colonization (p = 0.015) by C. albicans than LU in the 90-min and 48-hour periods. It can be concluded that both 3D-printed denture base resins are more prone to colonization by C. albicans, and that their surface free energy may be more likely associated with that colonization than their surface roughness.