Mechanical Reliability, Tooth Debonding Rates, and Patient Satisfaction of 3D-Printed vs. Conventionally Fabricated Complete Dentures: A 12-MonthRandomized Controlled Cross-Over Trial

Abstract

This randomized controlled crossover trial evaluated the mechanical reliability, cumulative tooth debonding rates, and patient-reported satisfaction of 3D-printed versus conventionally heat-polymerized complete dentures over a 12-month period. Forty-eight fully edentulous adults (mean age 63.7 ± 8.4 years) received both prosthesis types in random order, each worn for six months with a two-week washout interval. Primary outcomes included prosthesis fracture incidence, cumulative tooth debonding assessed by Kaplan–Meier analysis, and patient satisfaction measured using a 100- mm visual analogue scale (VAS). Forty-four participants completed the study protocol. Fracture incidence showed no significant difference between groups (15.9% for 3D-printed vs. 9.1% for conventional dentures; p = 0.34). However, 3D-printed dentures demonstrated significantly higher cumulative tooth debonding rates at 12 months (22.7% vs. 9.1%; log-rank p = 0.042). Patient satisfaction and OHIP-EDENT scores improved similarly in both groups, indicating comparable oral health-related quality of life outcomes despite the higher debonding risk associated with additive manufacturing workflows.