A Pilot Randomised Controlled Trial to Compare 3D Printed Versus Conventionally Fabricated Complete Dentures

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10.1922/EJPRD_2835Keeling09

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• Andrew Keeling
• Cecilie Osnes
• Krishan Davda
• Syeda Khalid
• Gillian Dukanovic
• Catherine Porter
• David Attrill
• Hugh Devlin
• Natalie Archer
• Farag Shuweihdi
• T Paul Hyde

Abstract

European Journal of Prosthodontics and Restorative Dentistry (2025) 33, 370–378

Keywords
3D Printing
Edentulous
Prosthodontics
Dentures

Authors
Andrew Keeling *

(BSc(Hons), BDS, PhD, MFGDP RCS(Eng)
FCGDent FHEA)

Cecilie Osnes *

A Pilot Randomised
Controlled Trial to
Compare 3D Printed Versus
Conventionally Fabricated
Complete Dentures

(BA(Hons), MSc, PhD)

Krishan Davda *

ABSTRACT

Syeda Khalid *

Objectives: This pilot randomised controlled trial assessed the acceptability of 3D
printed complete dentures versus conventionally manufactured dentures. It aimed to
identify the sample size needed for a full-scale trial and refine digital fabrication and trial
protocols. Methods: A multi-centre, double-blinded, cross-over design was used with 17
participants (14 completed), all aged 60+ and complete denture wearers. Each participant received 3D printed and conventional dentures, worn for eight weeks each. Tooth
positioning and denture shape were standardised. The OHIP-EDENT questionnaire measured comfort, retention, stability, and chewing efficiency. Results: A sample size of 35 is
recommended for a definitive trial. Participants preferred conventional dentures. Issues
with 3D printed dentures included unreliable tooth placement and structural failures.
Seven breakages (one denture broke four times) and six tooth debondings occured in the
3D printed group. Conclusions: A sample size of 35 participants is recommended for a
definitive trial, post adjustment. 3D printing offers potential benefits, but this study found
lower patient satisfaction and material challenges in the 3D printed dentures. Technical
and protocol refinements are needed before 3D printed dentures can be recommended
for routine use. Clinical Relevance: Until fabrication issues are resolved, conventional
dentures remain the more reliable option in prosthodontic care.

(BChD, MFDS, RCS(Ed))
(MSc, MBA)

Gillian Dukanovic *

(Research Dental Nurse Coordinator,
Qual-Cert Proficiency in Dental Surgery
Assistant (Leeds))

Catherine Porter *
(BA(Hons), PGCert)

David Attrill §

(BDS PhD FDS RCS(Ed) FDS RCS (Rest
Dent) FHEA)

Hugh Devlin ‡ ^

(BDS, MSc, PhD)

Natalie Archer §

(BDS MJDF (RCS Eng) PGCert (DentEd)
AFHEA)

Farag Shuweihdi *
(BSc, MSc, PhD)

T Paul Hyde *

(BChD, PhD, DGDP RCS (Eng), MGDS RCS
(Eng), FHEA)

INTRODUCTION

Address for Correspondence

Edentulism has a significant impact on oral and general health. Treatment with complete dentures is still the most economical and popular
option1. Despite a falling incidence of edentulism, the rise in the ageing
population is maintaining a large number of edentulous patients both in
the UK and globally2,3,4.

Andrew Keeling *
Email: a.j.keeling@leeds.ac.uk
* University of Leeds, Leeds LS2 9JT, UK
§

Birmingham Dental Hospital, Birmingham B5 7EG, UK

‡

University of Manchester, Manchester M13 9PL, UK

^ University of Bristol, Bristol BS8 1QU, UK

In the UK, 5% of the adult population are edentate5, with an uneven distribution based upon age, socio-economic factors, geographical location, and gender. For many of these patients in the United Kingdom, we can expect them
to rely on the National Health Service (NHS) to provide dental treatment due
to financial constraints. The quality of dentures that patients receive directly
impacts on their quality of life and nutritional status6. It follows that the nutritional status and the quality of life of edentulous individuals may be improved
by the provision of better-quality dentures.

Received: 04.11.2024
Accepted: 06.07.2025
doi: 10.1922/EJPRD_2835Keeling09

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