Abstract
Purpose: The present review aims to critically evaluate the dimensional accuracy, mechanical integrity, and clinical applicability of three-dimensional (3D)-printed dental prosthetics in comparison with conventional subtractive manufacturing techniques.
Materials and Methods: A systematic analysis of recent in vitro and clinical studies (2021–2026) was conducted, focusing on stereolithography (SLA), digital light processing (DLP), and selective laser melting (SLM) technologies. Parameters assessed included marginal and internal fit accuracy, flexural strength, surface hardness, and long-term aging behavior under thermocycling and water storage conditions.
Results: 3D-printed crowns demonstrated superior marginal fit (14 ± 5 μm) compared to milled counterparts (22 ± 4 μm), with statistically significant differences (p ≤ 0.022). Nanoparticle-reinforced 3D-printed resins achieved flexural strengths ranging from 80.02 to 114.60 MPa, exceeding ISO 20795-1 requirements (65 MPa). SLA technology consistently outperformed DLP in dimensional trueness, particularly for complex multi-unit fixed partial dentures. However, 3D-printed zirconia exhibited greater variability in mechanical properties due to porosity and processing parameters, though clinically acceptable values were achieved with optimized build orientations.
Conclusion: Additive manufacturing represents a transformative paradigm in prosthetic dentistry, offering enhanced fitting precision, material efficiency, and workflow streamlining. While milled zirconia remains the benchmark for predictability, advances in resin formulations, nanoparticle reinforcement, and post-polymerization protocols position 3D printing as a viable and increasingly preferred alternative for definitive dental restorations. (Open J Biomed Res 2026;5:34-42)