Trueness, Precision, fit of FDM printed vs multilayered milled dental restorations– An in vitro study.

European Journal of Prosthodontics and RestorativeDentistry (2025) 33, 428–437

Fused Deposition Modelling, subtractive manufacturing, Fixed Partial dentures, Standard Tessellation Language

Trueness, Precision, fit of FDM
printed vs multilayered milled
dental restorations– An in vitro
study.
Phd Scholar, Department of Prosthodontics, SRM DENTAL COLLEGE, Ramapuram,
Bharathi salai, Chennai91, Tamil Nadu, Email ID: ganny.gk@gmail.com , Orcid ID:
0009000486668198

1

R. GANESH KUMAR (MDS)1*, Venkat Rengasamy(MDS, PhD)2,
S. Prasanna Karthik(MDS)3,
,
S. Arul Kumar(MDS,PhD)4
M. Kiran kanna (BDS)

5

Professor, Department of Prosthodontics, SRM DENTAL COLLEGE, Ramapuram,
Bharathi Salai, Chennai91, Tamil nadu, Email ID: venkat.mdsphd@gmail.com Orcid ID:
0000000310595995

2

Professor, Department of Prosthodontics, SVDCH, The Tamil Nadu Dr.M.G.R.Medical
University, Email ID:prasanna6karthik@gmail.com , Orcid ID: 0009000196798947
3

⁴Professor, Department of Prosthodontics ,The Tamil Nadu Dr.M.G.R.Medical
University, Email ID: arulvel_85@yahoo.com, Orcid ID: 0000-0001-7809-72
5PG Student ,SVDCH, The Tamil Nadu Dr. M.G.R.Medical University, Email
ID: lookkiran008@gmail.com, Orcid ID: 0009-0001-4292-5058

Received: 11.11.2025 Accepted: 19.12.2025

Zirconia is extensively used for fixed dental prostheses (FDPs) owing to its high strength, biocompatibility, and favorable esthetics. Conventionally, zirconia FDPs are fabricated using subtractive manufacturing (SM) through CAD/CAM milling. Recently, additive manufacturing (AM), particularly fused deposition modelling (FDM), has gained attention as a potential alternative due to reduced material wastage, cost efficiency, and simplified fabrication. However, evidence regarding the accuracy of FDMfabricated zirconia FDPs remains limited.This in vitro comparative study evaluated the marginal fit, internal adaptation, trueness, and precision of zirconia fixed partial dentures fabricated using FDM and SM techniques. Twenty threeunit zirconia FDPs were fabricated from a single STL dataset, with ten specimens produced by FDM printing and ten by 5axis milling. All specimens were sintered under standardized conditions. Threedimensional deviation analysis was performed using Geomagic Control X software, and root mean square values were calculated. Statistical analysis was conducted using ttests and oneway ANOVA.Both groups demonstrated clinically acceptable marginal fit. FDMfabricated FDPs showed superior precision, while milled FDPs exhibited higher intaglio surface trueness. These findings suggest that FDM is a viable alternative for zirconia FDP fabrication, warranting further clinical evaluation. Background of the study: According to earlier researchers, printed zirconia crowns are reported as clinically acceptable, but milled crowns are more accurate. This study compares zirconia fixed partial denture (FPD) created using (FDM) fused deposition modeling technique, with traditionally milled FPDs. Aim: To compare the internal fit, trueness, and precision of zirconia fixed FPDs manufactured by using FDM (Fused Deposition Modelling) and the milling technique. Study Design: An in vitro comparative study evaluating twenty zirconia FPDs created using FDM (Fused Deposition Modelling) and Subtractive Manufacturing (SM) techniques.

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