Fabian Huettig

Additive Manufacturing: A Comparative Analysis of Dimensional Accuracy and Skin Texture Reproduction of Auricular Prostheses Replicas

PURPOSE The use of computer-aided design/computer-aided manufacturing (CAD/CAM) and additive manufacturing in maxillofacial prosthetics has been widely acknowledged. Rapid prototyping can be considered for manufacturing of auricular prostheses. Therefore, so-called prostheses replicas can be fabricated by digital means. The objective of this study was to identify a superior additive manufacturing method to fabricate auricular prosthesis replicas (APRs) within a digital workflow. MATERIALS AND METHODS Auricles of 23 healthy subjects (mean age of 37.8 years) were measured in vivo with respect to an anthropometrical protocol. Landmarks were volumized with fiducial balls for 3D scanning using a handheld structured light scanner. The 3D CAD dataset was postprocessed, and the same anthropometrical measurements were made in the CAD software with the digital lineal. Each CAD dataset was materialized using fused deposition modeling (FDM), selective laser sintering (SLS), and stereolithography (SL), constituting 53 APR samples. All distances between the landmarks were measured on the APRs. After the determination of the measurement error within the five data groups (in vivo, CAD, FDM, SLS, and SL), the mean values were compared using matched pairs method. To this, the in vivo and CAD dataset were set as references. Finally, the surface structure of the APRs was qualitatively evaluated with stereomicroscopy and profilometry to ascertain the level of skin detail reproduction. RESULTS The anthropometrical approach showed drawbacks in measuring the protrusion of the ears helix. The measurement error within all groups of measurements was calculated between 0.20 and 0.28 mm, implying a high reproducibility. The lowest mean differences of 53 produced APRs were found in FDM (0.43%) followed by SLS (0.54%) and SL (0.59%)--compared to in vivo, and again in FDM (0.20%) followed by SL (0.36%) and SLS (0.39%)--compared to CAD. None of these values exceed the threshold of clinical relevance (1.5%); however, the qualitative evaluation revealed slight shortcomings in skin reproduction for all methods: reproduction of skin details exceeding 0.192 mm in depth was feasible. CONCLUSION FDM showed the superior dimensional accuracy and best skin surface reproduction. Moreover, digital acquisition and CAD postprocessing seem to play a more important role in the outcome than the additive manufacturing method used.

Direct 3D printing of silicone facial prostheses: A preliminary experience in digital workflow

Direct silicone printing may be applied to the fabrication of maxillofacial prostheses, although its clinical feasibility is unknown. The present clinical report shows an early application of a directly printed silicone prosthesis for the rehabilitation of a nasal defect. Two extraoral scanning systems were used to capture the face and the defect. The virtual construction of the nasal prosthesis was performed with free-form software. Two prostheses were printed in silicone and post-processed by manual sealing and coloring. The clinical outcome was acceptable for an interim prosthesis; however, the marginal adaptation and color match were not satisfactory without further individualization.

Auricular Prostheses Produced by Means of Conventional and Digital Workflows: A Clinical Report on Esthetic Outcomes

The utilization of additive manufacturing (AM) technology for the production of auricular prostheses has been widely acknowledged. However, few studies and case history reports have evaluated the esthetic outcomes of AM prostheses compared to those of conventionally manufactured prostheses. In this case history report, three manufacturing approaches-conventional, indirect, and direct mold preparation-were assessed for their esthetic outcomes in the same patient.

Polishability and wear resistance of splint material for oral appliances produced with conventional, subtractive, and additive manufacturing

Occlusal splints to treat bruxism are commonly made from polymethylmethacrylate (PMMA) in a manual workflow (powder-liquid technique). Today digitalization allows a machine-based manufacturing in subtractive (milling) and additive (printing) means using industrial-made PMMA or comparable resins. An in-vitro study should assess the surface finish and screen the wear resistance of conventional and industrial materials. Therefore, a total of 30 specimens made from conventionally PMMA (group C; powder-liquid, Palapress), polycarbonate ingots (group S; innoBlanc splint plus), and light-curing resin (group A; VarseoWax splint) were polished to examine the surface roughness (Ra) by profilometry and further analyzed by SEM. The specimens were loaded with a steatite ball moving 5000 times along 1cm with 5N of surface pressure under constant wetting (artificial saliva). The total height of profile (Pt) was calculated by further profilometry of the specimens. All specimen showed initially comparable Ra values ranging between 0.06 and 0.05µm (SD = 0.01) after polishing. SEM investigations revealed no visual cues for scratches or irregularities in any group. After abrasion test, the comparison of the wear depths, revealed mean Pt values of 111.4µm (SD = 18.5) in C, 85.7µm (SD = 21.5) in S, and 99.1µm (SD = 21.5) in A, whereas the mean of S was statistically different from C (p = 0.025). No signs of abrasion were found on the steatite balls. All materials showed comparable polished surfaces and a similar scale of wear. It remains questionable if the detected statistical differences are of clinical relevance, but indicates the need for tests of novel materials, especially in additive manufacturing.

Complete rehabilitation of compromised full dentitions with adhesively bonded all-ceramic single-tooth restorations: Long-term outcome in patients with and without amelogenesis imperfecta

OBJECTIVES This clinical follow-up evaluated the long-term outcome of full-mouth rehabilitations with adhesively bonded all-ceramic restorations in patients suffering from amelogenesis imperfecta (AI) or affected by extensive tooth wear including a loss of the vertical dimension of occlusion. MATERIALS AND METHODS Included for evaluation were all patients treated with adhesively bonded monolithic single-tooth restorations made of silicate or lithium disilicate ceramics; allowing a maximum four missing teeth and a facial feldspathic veneering of LDS anterior crowns. After treatment, patients have been enrolled in a recall program for dental check-ups including quality assessment of the restorations. Patients answered the oral health impact profile (OHIP-14) at their last visit. RESULTS Seventeen patients (mean age = 35 ± 18 years) were observed up to 16.5 years (mean: 6.2 ± 3.8 years). 12 out of 450 restorations failed due to core fracture (n = 7), tooth fracture (n = 2), one secondary caries, one chip-off grade 3, and one fixed dental prosthesis due to discomfort. The overall mean survival rate of the single-tooth restorations was estimated 99.4% at 5 and 91.4% at 10 years. The overall mean success rate was estimated 92.6% at 5 and 81.4% at 10 years, mainly due to chip-offs and crack formation (27 out of 31 relative failures). The mean annual failure rates (AFR) range between 1.5 and 2% over the years, but non-AI patients were affected more frequently by early technical complications in the facial veneering of anteriors, resulting in an AFR ranging between 5.2 and 4%. Quality assessment revealed stable color, form and marginal integrity in all patients up to ten years. The distribution of OHIP values is comparable to the representative sample of healthy patients. CONCLUSION Adhesively bonded single-tooth restorations provided a high clinical quality in the long-run. However, while the survival and success were excellent in AI patients, restorations in non-AI patients were affected by a higher complication rate, likely related to a higher risk profile due to a history of bruxism and tooth wear.

All-ceramic prosthetic rehabilitation of a worn dentition: Use of a distal cantilever. Two-year follow-up.

The rehabilitation of heavily abraded occlusion in patients with parafunctional habits is a restorative challenge to the dentist. Use of all-ceramic systems in such cases is widely considered, but uncertainty over their resistance hinders their broad use. The authors would like to illustrate a possible approach by mixing two all-ceramic systems based on zirconium dioxide and lithium disilicate. A 48-year-old female patient attended with reduced vertical dimension in a full dentition. She suffered from craniomandibular (CMD) pain and desired an esthetic rehabilitation. Prosthodontic treatment was started in a pain-free condition, after correction of the vertical dimension with an occlusal splint, over four months. Determination of the treatment was based on the clinical findings: IPS e.max® ZirCAD frameworks veneered with IPS e.max® Ceram were used for discolored retainers or subgingival finishing lines. All the rest received IPS e.max® Press crowns. A zirconia-based, single-tooth-retained distal cantilever reconstruction was used to replace a missing second molar. No technical or biological complication was observed 24 months after treatment. The patient was highly satisfied and pain-free.

The challenge of erosion and minimally invasive rehabilitation of dentitions with BEWE grade 4.

OBJECTIVE Dental erosion is a challenging problem. In addition to dental erosions dental effects, general health also has to be taken into account. In particular, consumption of newly marketed beverages as well as psychosomatic and gastroesophageal disorders contribute to decayed dentitions. Without a comprehensive method for implementing preventive concepts in daily practice, many young adults will require large-scale, long-term treatment in the near future. Thus, dentists should be aware of preventative methods, prerequisites for rehabilitation, and treatment concepts available for such cases. Clinical Considerations: Patients with severe dental erosions are often young adults who suffer from hypersensitivity and loss of vertical dimension and occlusal structure. Modern ceramics enable a minimally invasive, esthetic, and rugged approach for achieving a complete rehabilitation. In particular, monolithic restorations using lithium disilicate or zirconia-reinforced lithium silicate seem to be promising treatment strategies. In addition to the dentist, the dental technician needs to be educated and experienced with complex occlusal and functional rehabilitation. Currently, clinical longterm experiences have only been reported for adhesively bonded silicate and lithium disilicate restorations. CONCLUSION Heat-pressed and adhesively bonded monolithic lithium disilicate restoration fulfills all needs of complex treatment and long-term rehabilitation in young adults with dental erosion. Even if minimal tooth preparation is needed, in healthy teeth, adhesively bonded restorations require minimal thickness of the ceramic layer to obtain function, durability, and esthetics for this type of patient.

A modified shark-fin test simulating the single-step/double-mix technique: A comparison of three groups of elastomers

The shark-fin test was modified to convey the clinical application of a single-step/double-mix technique assessing the behavior of two viscosities applied at one point in time. A medium and light body polyether (PE), a medium and light body polyvinylsiloxane (PVS), and a medium as well as heavy and light body vinyl polyether silicone (PVXE) impression material were analyzed solely, and in a layered mixture of 1:1 and 3:1 at working times of 50, 80, and 120 s. The fin heights were measured with a digital ruler. The wettability was measured 50 and 80 s after mixing by drop shape analysis. The results showed a synergistic effect of the medium and light body PE. This was not observed in PVXE and PVS. Interestingly, PVXE showed an antagonistic flow behavior in 3:1 mixture with medium body. PVXE was more hydrophilic than PE and PVS. Future rheological studies should clarify the detected flow effects.

Objects build orientation, positioning, and curing influence dimensional accuracy and flexural properties of stereolithographically printed resin

OBJECTIVE To evaluate the influence of printing parameters on flexural properties and accuracy of SLA-printed standard objects. METHODS Thirty specimens were printed in 0°, 45° and 90° orientation. Fourth nine more specimens were printed evenly on the build platform. forty more specimens were printed and polymerized with three curing unit. Length, height and width was measured three times for each specimen and compared to the original dimensions. Afterwards all specimens underwent a three-point-bending test to assess their flexural properties. One way ANOVA and the Post-Hoc all pairs Tukey-Kramer HSD test were used for data evaluation. RESULTS The print orientation influences the printing accuracy. The parameters printed along the Z-axis are particularly prone to inaccuracies. Specimens with 45° orientation were found to be the most accurate. Object printed on the borders of build platform a rather prone to inaccuracies than those in the center. The 90° specimens with layer orientation parallel to the axial load showed the superior flexural strength and flexural modulus. The use of different curing unit is unlikely to affect the objects printing accuracy and flexural properties. SIGNIFICANCE The anisotropical behavior of printed specimens with regards to build orientation and positioning was revealed. The understanding of how the adjustable printing parameter influence the printing outcome is important for a precise fabrication of surgical guides. Inaccuracies up to 10% along the Z-axis, as revealed in the present study,may restrict an accurate implant placement.

Reporting of dental status from full-arch radiographs: Descriptive analysis and methodological aspects.

AIM To identify standards, how entities of dental status are assessed and reported from full-arch radiographs of adults. METHODS A PubMed (Medline) search was performed in November 2011. Literature had to report at least one out of four defined entities using radiographs: number of teeth or implants; caries, fillings or restorations; root-canal fillings and apical health; alveolar bone level. Cohorts included to the study had to be of adult age. Methods of radiographic assessment were noted and checked for the later mode of report in text, tables or diagrams. For comparability, the encountered mode of report was operationalized to a logical expression. RESULTS Thirty-seven out of 199 articles were evaluated via full-text review. Only one article reported all four entities. Eight articles reported at the maximum 3 comparable entities. However, comparability is impeded because of the usage of absolute or relative frequency, mean or median values as well as grouping. Furthermore the methods of assessment were different or not described sufficiently. Consequently, established sum scores turned out to be highly questionable, too. The amount of missing data within all studies remained unclear. It is even so remissed to mention supernumerary and aplased teeth as well as the count of third molars. CONCLUSION Data about dental findings from radiographs is, if at all possible, only comparable with serious limitations. A standardization of both, assessing and reporting entities of dental status from radiographs is missing and has to be established within a report guideline.