Influence of resin type and new-generation post-processing cleaning solutions on the fabrication trueness and adaptation of additively manufactured denture bases.

OBJECTIVES: To evaluate the fabrication trueness and adaptation of additively manufactured denture bases made from different resins and postprocessed with different cleaning solutions. METHODS: An edentulous maxillary model was scanned to design a reference denture base file. This reference file was used to fabricate 96 denture bases from three resins (DB, DentaBASE; DT, Denturetec; FD, FREEPRINT Denture) that were cleaned with four solutions (MES, Weiton-3D Resin Cleaner; WBS, Print Cleaning Concentrate; BDS, Cleaning Fluid Bio; isopropyl alcohol [IPA]) (n = 8). All bases were scanned for digital deviation (external, intaglio, and overall root mean square) and adaptation (triple scan, average gap) analyses. Data were analyzed with two-way analysis of variance and Bonferroni-corrected post hoc tests (α = 0.05). RESULTS: FD bases had the lowest and DT bases had the highest intaglio and overall deviations across tested solutions (P ≤ 0.017). DT bases also had the highest external deviations within WBS, BDS, and IPA (P < 0.001). IPA led to higher external and overall deviations than MES for DT bases (P = 0.001). DT bases exhibited the highest gaps, whereas BDS cleaning increased their gaps compared with MES and IPA cleaning (P ≤ 0.044). CONCLUSIONS: FD bases mostly had the highest and DT bases mostly had the lowest trueness. Tested cleaning solutions' effect on fabrication trueness was minimal and potentially clinically negligible. DT bases showed the poorest adaptation, irrespective of the solution. CLINICAL SIGNIFICANCE: Maxillary FD denture bases may require less chairside adjustments than DT and DB bases, and DB bases might be more prone to retention issues while using tested cleaning solutions. Alcohol-free MES and WBS may be preferred over IPA to clean denture bases in tested resins without compromising their trueness and adaptation.