Complications and challenges associated with 3D printed complete dentures: A narrative review.

Abstract Background: Three-dimensional (3D) printing has emerged as a significant innovation in prosthodontics, offering advantages such as rapid fabrication, enhanced customization, and digital reproducibility in the production of complete dentures. Despite these benefits, several complications and clinical challenges associated with the use of 3D printed dentures remain inadequately addressed in the current literature. Aim: This narrative review aims to critically evaluate the complications and problems associated with 3D printed complete dentures, focusing on material limitations, fabrication accuracy, mechanical performance, esthetic outcomes, clinical adaptability, and operator-related errors. Results: Evidence from recent in vitro and clinical studies suggests that 3D printed denture bases commonly exhibit lower flexural strength and fracture resistance compared to conventionally processed acrylic resins. Furthermore, bonding failures between printed bases and denture teeth, suboptimal esthetic outcomes, limited polishability, and color stability are frequently reported. In addition to technical limitations, human-related errors such as improper digital impression acquisition, inadequate design of occlusal and anatomical features, incorrect print settings, suboptimal post-processing, and poor handling of support structures during printing or finishing may significantly affect the final prosthesis. While some studies demonstrate acceptable short-term clinical outcomes, there is a lack of robust long-term data supporting their durability and effectiveness. Conclusion: Although 3D printed complete dentures represent a promising advancement in prosthodontic care. To reduce errors, increase workflow dependability, and boost clinical acceptance of 3D printed dentures, it is imperative to conduct ongoing research and innovation in printing technology, operator training, and standardized protocols. Keywords: 3D printed dentures, Additive manufacturing, Complete dentures, Denture complications, Digital prosthodontics.