Dimensional reliability in CAD/CAM production of complete denture bases: A comparative study of milling and various 3D printing technologies

This study aims to assess the dimensional accuracy of complete denture bases fabricated from different CAD/CAM technologies and a conventional method, including milling (CNC), PolyJet (PJ), laser sintering (SLS), digital light processing (DLP), and injection molding (IM). It also examines the influence of the removal of technology-specific connectors or support structures when present. Denture base surfaces were digitized using a laboratory scanner, and virtual measurement points were calculated with tetrahedral reference geometries. Defined distances were measured in all spatial directions and compared to design data (p<0.05), revealing significant differences in sagittal (p=0.004), transversal (p<0.001), and vertical (p<0.001) dimensions. Connector removal had no significant impact for CNC but significantly affected DLP. All technologies yielded clinically acceptable results, with CNC milling demonstrating the best overall outcome.