Clinical and Laboratory Assessment of 3D Printing Orientation and Film Thickness on the Accuracy and Patient Satisfaction of Maxillary Complete Dentures

This prospective randomized crossover clinical trial is designed to evaluate and compare the effect of different three-dimensional (3D) printing orientations and layer thicknesses on the trueness, dimensional accuracy, and patient satisfaction of maxillary complete dentures in completely edentulous patients.

The study will include completely edentulous patients requiring maxillary and mandibular complete dentures. Each participant will receive two maxillary complete dentures fabricated using 3D printing technology with the same printing orientation but two different layer thicknesses (50 μm and 100 μm) in a crossover sequence. Participants will be randomly allocated to one of three printing orientation groups (0°, 45°, or 90°), with five participants in each group.

The three printing orientations being compared are:

1. 0° Build Orientation: Maxillary denture bases will be fabricated at a 0° printing orientation using both 50 μm and 100 μm layer thicknesses.
2. 45° Build Orientation: Maxillary denture bases will be fabricated at a 45° printing orientation using both 50 μm and 100 μm layer thicknesses.
3. 90° Build Orientation: Maxillary denture bases will be fabricated at a 90° printing orientation using both 50 μm and 100 μm layer thicknesses.

Each participant will wear each denture for a three-month evaluation period. The primary outcomes of the study are trueness of the printed denture bases, assessed by comparing the scanned denture base STL files with the original CAD design, and patient satisfaction, evaluated using a Visual Analogue Scale (VAS) for aesthetics, speech, masticatory efficiency, hygiene, and comfort. Dimensional deviation of the denture bases will also be assessed through three-dimensional superimposition analysis at denture insertion and after three months of use.