Palatal Vault Depth Affects the Accuracy of the Intaglio Surface of Complete Maxillary Denture Bases Manufactured Through Additive Manufacturing

Background/Objectives: The purpose of this in vitro study is to evaluate the effect varying palatal vault depths have on the accuracy of complete maxillary denture bases fabricated using additive manufacturing technology. Methods: One hundred complete maxillary denture bases were manufactured on two different digital light processing (DLP) dental 3D printers at five different palatal depths. After manufacturing, the denture bases were post-cured, scanned, and then analyzed in metrology software. Statistically significant differences were determined using two-way ANOVA tests for normally distributed data and the Kruskal–Wallis test for non-normally distributed data. Color deviation maps were used to give clinical relevance to the results. Results: Significant differences were found for both printers among some groups for the different palatal depths. In relation to the negative mean deviation, the data revealed that the NextDent printers were the least accurate (0.047 ± 0.004) in the group with the deepest palate. The positive mean deviation revealed the most deviation (0.077 ± 0.009) in the group with the deepest palate, which was also mirrored in the Asiga printer (0.050 ± 0.002). The color deviation maps revealed areas of positive and negative average deviation in all groups. The effect of the printer model (p = 0.007) and palatal depth (p = 0.04) on negative average deviation was significant. The effect of the interaction of printer and palatal depth was also significant (p = 0.001). Conclusion: Deeper palatal vaults are associated with higher deviation in DLP 3D-printed complete maxillary denture bases manufactured through additive manufacturing.