Fit Accuracy and Shear Peel Bond Strength of CAD/CAM-Fabricated Versus Conventional Stainless Steel Space Maintainers: In Vitro Comparative Study

Background/Objectives: The precision and bonding reliability of space maintainers are critical to their clinical success longevity. This study aimed to evaluate and compare the fit accuracy and shear peel bond strength of digitally fabricated space maintainers—cobalt–chromium (Co-Cr) and polyetheretherketone (PEEK)—against conventional space maintainers. Methods: Seventy-eight space maintainer bands were fabricated—milled PEEK, selective laser-melted (SLM; an additive manufacturing technique) Co-Cr, and conventional stainless steel (SS)—and tested. Fit accuracy was evaluated on 39 bands by measuring the root mean square (RMS) deviation from a master model using digital 3D analysis. Shear peel bond strength (SPBS) was tested on another 39 samples using a universal testing machine, and the adhesive remnant index (ARI) was recorded after debonding. Statistical analyses included a Welch ANOVA for fit accuracy and the Kruskal–Wallis test for the SPBS test; the ARI was analyzed using Fisher’s exact test (significance level p < 0.05). Results: Digitally fabricated bands demonstrated significantly higher fit accuracy than the stainless steel bands (mean RMS deviation: Co-Cr = 0.151 mm, PEEK = 0.152 mm, SS = 0.344 mm; p < 0.001). Co-Cr and PEEK demonstrated comparable adaptation. In contrast, bond strength was significantly greater in Co-Cr (1.657 MPa) and SS (1.481 MPa) compared to PEEK (0.393 MPa). ARI distribution varied significantly across the three groups. Conclusions: Both milled PEEK and Co-Cr bands demonstrated excellent adaptation compared with conventional SS bands. However, Co-Cr exhibited reliable bonding performance, yet PEEK may require additional surface treatment or bonding optimization to enhance adhesion.