Clinical Assessment of 3D-Printed Versus Conventional Occlusal Devices: Best-Fit, Roughness, Wear, and Treatment Capability

This study investigates the accuracy of stereolithography (SLA)-printed occlusal devices fabricated at orientations of 0 • and 45 • , addressing a gap in the literature regarding printing orientation, technology and clinical performance.Despite their nascent application, the clinical performance of these materials remains largely unexplored.The primary objective was to evaluate the clinical efficacy of 3D-printed occlusal devices (OC) in a prospective, double-blind study involving 40 participants divided into four groups: conventionally fabricated polymethyl methacrylate (PMMA) occlusal devices (CPMMA), CAD/CAM milled PMMA (MPMMA), and 3D-printed OCs at 0 degrees (3D 0 • ) and 45 degrees (3D 45 • ).Conventional impressions and gypsum casts were digitized and designed for milling from PMMA blocks, while the 3D-printed groups used Dental LT resin (Formlabs, Sommerville, MA, USA) in a Form 2 printer (Formlabs, MA, USA).Clinical assessments were conducted at baseline and six months post-treatment, focusing on OC surface roughness, OC surface wear, antagonist tooth wear, occlusal device fit, and therapeutic efficacy.One-way ANOVA and post hoc tests were applied for statistical analysis.Results showed no significant therapeutic differences among groups, although all participants exhibited improvements in palpation and mandibular movement scores (p > 0.001).No significant difference was observed in surface wear between the MPMMA and 3D 0 • groups, while the difference between the other groups was significant (p < 0.001).Significant antagonist tooth wear variations (p < 0.001) were noted, with the MPMMA and 3D 0 • groups showing less wear compared to the control group.The findings indicate that 3D-printed occlusal devices yield clinically acceptable outcomes, demonstrating performance comparable to traditional materials, with printing orientation potentially influencing antagonist tooth wear.The 3D-printed OC demonstrates adequate surface roughness, wear resistance, device fit, and therapeutic efficacy.