Search Results (260)

This study explores the fabrication of hydrophobic surfaces on polymer components via Digital Light Processing (DLP), with emphases on how texture geometry, feature dimensions, and resin type influence surface wettability. Square and cylindrical microtextures were fabricated and evaluated using static contact angle measurements. Square-shaped structures demonstrated enhanced hydrophobicity, with contact angles reaching 133.6°, compared to approximately 100° for cylindrical counterparts of identical dimensions. Increasing pillar height to 521 µm enhanced hydrophobicity by approximately 15%, while decreasing pillar spacing to 150 µm increased contact angles from 86.8° to 106°, highlighting the role of microstructure density. For square-shaped structures, the addition of a hydrophobic agent at 3 wt.% resulted in a contact angle of 123.4°, representing a 44% improvement over the untreated sample. These findings underscore the combined influence of resin chemistry, surface texture design, and dimensional parameters on wettability behavior. Although superhydrophobicity (contact angle > 150°) was not achieved, the study demonstrates notable advancements in optimizing hydrophobicity through DLP printing. Overall, the results support DLP as a scalable and cost-effective approach for engineering functional surfaces suited to self-cleaning, biomedical, and anti-fouling applications. Full article

Additive manufacturing (3D printing) using Computer-Aided Design (CAD) has emerged as a cost-effective alternative to subtractive milling in restorative dentistry, offering reduced material waste and lower production costs. This study aimed to compare the physical properties, specifically water sorption, water solubility, and surface roughness, of milled and 3D-printed hybrid resin composite materials. Standardized disk-shaped samples were fabricated using a digital workflow. The additive group included 15 samples printed with a DLP printer using CROWNTEC resin at three different orientations (0°, 45°, and 90°), with five samples prepared at each printing orientation. The subtractive group consisted of specimens milled from the SHOFU DISK hybrid resin composite. Surface roughness samples were also prepared for both methods. Statistical analysis using one-way ANOVA, post hoc tests, and paired t-tests revealed significant differences among groups in all tested properties (p < 0.001). Subtractive manufacturing consistently outperformed additive techniques. Among the printed groups, orientation at 0° showed the most favorable outcomes. Moreover, polishing significantly improved surface roughness in both manufacturing methods (p < 0.001). These findings emphasize the influence of the fabrication method and printing orientation on the clinical performance of hybrid resin composites, highlighting the importance of polishing in optimizing the surface quality for 3D-printed restorations. Full article

This study aimed to develop an innovative resin composite with anti-biofouling properties, tailored to prosthesis fabrication in dentistry using a digital light processing (DLP) 3D-printing technique. The resin composite was formulated using a blend of dental monomers, with the integration of 2-methacryloyloxylethyl phosphorylcholine (MPC) with anti-biofouling behavior and γ-MPS-treated silica-zirconia powder for simultaneous mechanical reinforcement. The overall characterization of the resin composite was carried out using various contents of MPC incorporated into the resin (0–7 wt%) for examining the rheological behavior, photopolymerization, flexural strength/modulus, microstructure and anti-biofouling efficiency. The resin composite demonstrated a significant reduction in bacterial adhesion (97.4% for E. coli and 86.5% for S. aureus) and protein adsorption (reduced OD value from 1.3 ± 0.4 to 0.8 ± 0.2) with 7 wt% of MPC incorporation, without interfering with photopolymerization to demonstrate potential suitability for 3D printing without issues (p < 0.01, and p < 0.05, respectively). The incorporation and optimization of γ-MPS-treated silica-zirconia powder (10–40 vol%) enhanced mechanical properties, leading to a reasonable flexural strength (103.4 ± 6.1 MPa) and a flexural modulus (4.3 ± 0.4 GPa) at 30 vol% (n = 6). However, a further increase to 40 vol% resulted in a reduction in flexural strength and modulus; nevertheless, the results were above ISO 10477 standards for dental materials. Full article

Successful dental implant therapy relies on accurate planning and placement, e.g., through static, computer-aided implant surgery using CAD/CAM-fabricated surgical guides. This study examined production methods’ influence on surgical guide sleeve housing geometry. A model with two edentulous spaces was digitized using intraoral scanning and CBCT, and two virtually positioned implants were planned. Ten guides per group were produced using milling (MCX5), DLP printing (ASIGA and SHERA), and SLA printing (FORM), printing with 50 µm and 100 µm layers each. Each guide (n = 70) was then digitized using an industrial scanner before and after sterilization. Superimposition of the actual guide data with the reference data allowed for evaluation of deviations at the drill sleeve housing along the x-, y-, z-, and dxyz-axes. Descriptive and statistical evaluation was performed (significance level: p ≤ 0.0125). Significant differences existed among the production methods: Milling and SLA showed higher deviations than the DLP group (p < 0.001). Milled guides post-sterilization showed the highest deviations (0.352 ± 0.08 mm), while one DLP printer at 50 μm layer thickness showed lowest deviations (0.091 ± 0.04 mm). The layer thickness was insignificant, whereas sterilization increased deviation (p < 0.001). DLP produced the most precise implant surgical guides. All 3D printers were suitable for fabricating clinically acceptable surgical guides. Full article

Background: Limited data are available regarding the mechanical performance of 3D-printed fixed partial dentures (FPDs) fabricated from different materials and connector geometries. The purpose of this in vitro study was to evaluate the influence of connector size and material type on the fracture resistance of three-unit posterior FPDs fabricated with two commercially available 3D-printable dental resins. Methods: A standardized metal model with two cylindrical abutments was used to design three-unit FPDs. A total of sixty samples were produced, considering three connector sizes (3 × 3 mm, 4 × 4 mm, and 5 × 5 mm) and two different resins: Temp Print (GC Corp., Tokyo, Japan) and V-Print c&b temp (Voco GmbH, Cuxhaven, Germany) (n = 10). Specimens were fabricated with a DLP printer (Asiga MAX UV), post-processed per manufacturer recommendations, and tested for fracture resistance under occlusal loading using a universal testing machine. Data were analyzed using nonparametric tests (Mann–Whitney U and Kruskal–Wallis; α = 0.05). Results: Significant differences were found between material and connector size groups (p < 0.001). Temp Print (GC Corp., Tokyo, Japan) demonstrated higher mean fracture loads (792.34 ± 578.36 N) compared to V-Print c&b temp (Voco GmbH, Cuxhaven, Germany) (359.74 ± 131.64 N), with statistically significant differences at 4 × 4 and 5 × 5 mm connectors. Fracture strength proportionally increased with connector size. FPDs with 5 × 5 mm connectors showed the highest resistance, reaching values above 1500 N. Conclusions: Both connector geometry and material composition significantly affected the fracture resistance of 3D-printed FPDs. Larger connector dimensions and the use of Temp Print (GC Corp., Tokyo, Japan) resin enhanced mechanical performance. Full article

In this work, bio-based thermoelectric composites were developed using acrylated epoxidized soybean oil (AESO) as the polymer matrix and bismuth telluride (Bi₂Te₃) as the thermoelectric filler. The materials were formulated for both UV-curing and thermal-curing processes, with a focus on Digital Light Processing (DLP) 3D printing. Although UV curing proved ineffective at high filler concentrations due to the light opacity of Bi₂Te₃, thermal curing enabled the fabrication of stable, homogeneously dispersed composites. The samples were thoroughly characterized through rheology, FTIR, TGA, XRD, SEM, and density measurements. Thermoelectric performance was assessed under a 70 °C temperature gradient, with Seebeck coefficients reaching up to 51 µV/K. Accelerated chemical degradation studies in basic media confirmed the degradability of the matrix. The results demonstrate the feasibility of combining additive manufacturing with sustainable materials for low-power thermoelectric energy harvesting applications. Full article

Background/Objectives: The introduction of composite attachments has greatly improved orthodontic aligner therapy, through better force delivery, more predictable movements, and enhanced retention. This in vitro study aims to present and investigate an innovative digital protocol for aligner attachment fabrication incorporating the latest 3D technology used in dentistry. Methods: A virtual attachment measuring 2.5 × 2 × 2 mm was designed using computer-aided design (CAD) software (Meshmixer, Autodesk Inc., San Francisco, CA, USA) and exported as an individual STL file. The attachments were fabricated using a digital light processing (DLP) 3D printer (model: Elegoo 4 DLP, Shenzhen, China) and a dental-grade biocompatible resin. A custom 3D-printed placement guide was used to ensure precise positioning of the attachments on the printed maxillary dental models. A flowable resin was applied to secure the attachments in place. Following attachment placement, the models were scanned using a laboratory desktop scanner (Optical 3D Smart Big, Open Technologies, Milano, Italy) and three intraoral scanners: iTero Element (Align Technology, Tempe, AZ, USA), Aoral 2, and Aoral 3 (Shining 3D, Hangzhou, China). Results: Upon comparison, the scans revealed that the iTero Element exhibited the highest precision, particularly in the attachment, with an RMSE of 0.022 mm and 95.04% of measurements falling within a ±100 µm tolerance. The Aoral 2 scanner showed greater variability, with the highest RMSE (0.041 mm) in the incisor area and wider deviation margins. Despite this, all scanners produced results within clinically acceptable limits. Conclusions: In the future, custom attachments made by 3D printing could be a valid alternative to the traditional composite attachments when it comes to improving aligner attachment production. While these preliminary findings support the potential applicability of such workflows, further in vivo research is necessary to confirm clinical usability. Full article

The dimensional accuracy of 3D-printed edentulous jaw models is critical for successful prosthetic treatment outcomes. This study investigated the accuracy of 3D-printed working models of a completely edentulous jaw through comparative analysis of digital images generated by three laboratory scanners. A reference plaster model of a mandibular edentulous arch was digitized and used to produce ten resin models via digital light processing (DLP) technology. Each model was scanned using three different laboratory scanners: AutoScan-DS-EX, AutoScan-DS-EX Pro(H), and Optical 3D Scanner Vinyl. Digital comparison was performed using specialized software, evaluating the root mean square (RMS) deviation and percentage of values within an acceptable deviation range ±0.05 mm. All printed models showed significant deviations from the reference model (p < 0.05), with RMS values ranging from 109.2–139.7 µm and acceptable deviation percentages ranging from 29.34 to 32.31%. The mean precision RMS value was 66.37 µm. The mean intraclass correlation coefficient of 0.544 indicated moderate precision. Optical 3D Scanner Vinyl demonstrated the highest consistency, while AutoScan-DS-EX Pro(H) showed maximum variability. No statistically significant differences were found between scanners (p = 0.075). While the investigated scanners demonstrated reliable performance and sufficient accuracy, the additive manufacturing process introduced clinically significant deviations, highlighting the importance of verification between printed models and their digital originals before proceeding with clinical stages. Clinical practice should prioritize scanning systems with advanced software algorithms over those with superior hardware specifications alone. Full article

This study aimed to investigate the bonding strength and durability of titanium alloys bonded to zirconia-based materials produced using subtractive and additive digital methods. Two titanium alloy groups (N = 20) and two zirconia ceramic groups (N = 60) were fabricated using CAD/CAM milling from prefabricated discs (Ti-ML and Zr-ML), and 3D printing via SLM (Ti-3D) and DLP/LCM systems (Zr-3D). The specimens were bonded with dental cement to form four test groups: Zr-ML/Ti-ML, Zr-ML/Ti-3D, Zr-3D/Ti-ML, and Zr-3D/Ti-3D. Half of the specimens in each group underwent thermocycling to assess the effect of aging on bond strength. The density, microhardness, and surface morphology were evaluated, along with the shear bond strength and failure modes of the resin composites. Statistical differences were analyzed using one-way ANOVA and Tukey’s HSD test across all groups. The 3D-printed specimens of both materials exhibited higher microhardness and lower surface roughness than the milled specimens. The shear bond strength (SBS) was the highest in the Ti-ML/Zr-ML combination group before and after thermocycling, which had more cohesive failures, whereas the lowest bond strength was observed in the Ti-3D/Zr-ML group. The adhesion between titanium and zirconia-based materials was the strongest when both were fabricated using subtractive methods, followed by additive and mixed-method combinations. Full article

Three-dimensional (3D) printing has emerged as a transformative technology in dental splint fabrication, offering significant advancements in customization, production speed, material efficiency, and patient comfort. This comprehensive review synthesizes the current literature on the clinical use, benefits, limitations, and future directions of 3D-printed dental splints across various disciplines, including prosthodontics, orthodontics, oral surgery, and restorative dentistry. Key 3D printing technologies such as stereolithography (SLA), digital light processing (DLP), and material jetting are discussed, along with the properties of contemporary photopolymer resins used in splint fabrication. Evidence indicates that while 3D-printed splints generally meet ISO standards for flexural strength and wear resistance, their mechanical properties are often 15–30% lower than those of heat-cured PMMA in head-to-head tests (flexural strength range 50–100 MPa vs. PMMA 100–130 MPa), and study-to-study variability is high. Some reports even show significantly reduced hardness and fatigue resistance in certain resins, underscoring material-specific heterogeneity. Clinical applications reviewed include occlusal stabilization for bruxism and temporomandibular disorders, surgical wafers for orthognathic procedures, orthodontic retainers, and endodontic guides. While current limitations include material aging, post-processing complexity, and variability in long-term outcomes, ongoing innovations—such as flexible resins, multi-material printing, and AI-driven design—hold promise for broader adoption. The review concludes with evidence-based clinical recommendations and identifies critical research gaps, particularly regarding long-term durability, pediatric applications, and quality control standards. This review supports the growing role of 3D printing as an efficient and versatile tool for delivering high-quality splint therapy in modern dental practice. Full article

As three-dimensional (3D) printing becomes increasingly prevalent in microfluidic system fabrication, the demand for high precision has become critical. Among various 3D printing technologies, light-curing-based methods offer superior resolution and are particularly well suited for fabricating microfluidic channels and associated micron-scale components. Two-photon polymerization (TPP), one such method, can achieve ultra-high resolution at the submicron level. However, its severely limited printable volume and high operational costs significantly constrain its practicality for real-world applications. In contrast, digital light processing (DLP) 3D printing provides a more balanced alternative, offering operational convenience, lower cost, and print dimensions that are more compatible with practical microfluidic needs. Despite these advantages, most commercial DLP systems still struggle to fabricate intricate, high-resolution structures—particularly curve, thin-walled, or hollow ones—due to over-curing and interlayer adhesion issues. In this study, we developed a DLP-based projection micro-stereolithography (PμSL) system with a simple optical reconfiguration and fine-tuned its parameters to overcome limitations in printing precise and intricate structures. For demonstration, we selected an Archimedes microscrew as the target structure, as it serves as a key component in microfluidic micromixers. Based on our previous study, the most effective design was selected and fabricated in accordance with practical microfluidic dimensions. The PμSL system developed in this study, along with optimized parameters, provides a reference for applying DLP 3D printing in high-precision microfabrication and advancing microfluidic component development. Full article

The Internet of Things (IoT) is one of the pivotal technologies driving the digital transformation of industry, business, and personal life. Along with new opportunities, the exponential growth of IoT devices also brings environmental challenges, driven by the increasing accumulation of e-waste. This paper introduces a novel, compact, cubic-shaped rectenna with a 3D-printed composite substrate featuring five identical patches. The design aims to integrate RF energy harvesting technology with eco-friendly materials, enabling its application in powering next-generation sustainable IoT systems. Due to its symmetrical design, each patch antenna achieves a bandwidth of 130 MHz within the frequency range of 2.4 GHz to 2.57 GHz, with a maximum efficiency of 60.5% and an excellent isolation of below −25 dB between adjacent patch antennas. Furthermore, measurements of the rectifier circuit indicate a maximum conversion efficiency of 33%, which is comparable to that of other rectennas made on 3D-printed substrates. The proposed visually unobtrusive design not only enhances compactness but also allows the proposed rectenna to harvest RF energy from nearly all directions. Full article

Three-dimensional printing is rapidly growing in applied dentistry. In order to print faster, increase workflow, and minimize the consumption of resin material, it is important to use the right printer and the correct printing orientation. The objective of the present report is to analyze the flexural strength of specimens realized with two different dental light-curing resins (Keyguide and C&B) obtained from two different Digital Light Processing (DLP) 3D printers. Different printing orientations (0°, 45°, and 90°) were evaluated. 3D Builder, MeshMixer, RayWare, and Chitubox software were used to design the resin specimens. A total of 15 Keyguide and 15 C&B specimens in the shape of a rectangular parallelepiped, with dimensions of 2 mm × 2 mm × 25 mm, were obtained with the Sprintray Moonray S 3D printer, and the 15 Keyguide and 15 C&B specimens presented the same characteristics as those printed using the Moon Night printer. Prior to sample printing, a calibration protocol (tolerance test and dimensional accuracy test) was performed using RayWare software. This procedure allowed compensation for resin shrinkage or expansion, thus ensuring dimensional consistency in all printed samples. Each resin specimen, after printing and post-processing (MoonWash 2 and MoonLight 2), was subjected to a mechanical test with a universal testing machine. After breaking the specimen, the flexural strength values were recorded with computer software (Bluehill, Instron Corporation, Canton, MA, USA). According to the results obtained, the printing orientation of the specimens does not affect the flexural strength of the two materials examined. However, at the maximum load, some differences emerged for both materials printed with the Moon Night printer, depending on their build angle. Both light-cured resins tested had a higher maximum load resistance when printed with the newer Moon Night printer. This result could be due to the Moon Night printer’s better construction characteristics compared to those of the Sprintray or to issues related to the dimensional calibration of the specimens. Full article

The development of high-impact denture base formulations that are suitable for digital light processing (DLP) 3D printing is demanding. Indeed, a combination of high flexural strength/modulus and high fracture toughness is required. In this contribution, eight urethane macromonomers (UMs1-8) were synthesized in a one-pot, two-step procedure. Several rigid diols were first reacted with two equivalents of trimethylhexamethylene diisocyanate. The resulting diisocyanates were subsequently end-capped with a free-radically polymerizable monomer bearing a hydroxy group. UMs1-8 were combined with the monofunctional monomer (octahydro-4,7-methano-1H-indenyl)methyl acrylate and a poly(ε-caprolactone)-polydimethylsiloxane-poly(ε-caprolactone) (PCL-PDMS-PCL) triblock copolymer (BCP1) as a toughening agent. The double-bond conversion, glass transition temperature (T_g), and mechanical properties (flexural strength/modulus, fracture toughness) of corresponding light-cured materials were measured (cured in a mold using a light-curing unit). The results showed that the incorporation of BCP1 was highly efficient at significantly increasing the fracture toughness, as long as the obtained networks exhibited a low crosslink density. The structure of the urethane macromonomer (nature of the rigid group in the spacer; nature and number of polymerizable groups) was demonstrated to be crucial to reach the desired properties (balance between flexural strength/modulus and fracture toughness). Amongst the evaluated macromonomers, UM1 and UM2 were particularly promising. By correctly adjusting the BCP1 content, light-cured formulations based on those two urethane dimethacrylates were able to fulfill ISO20795-1:2013 standard requirements regarding high-impact materials. These formulations are therefore suitable for the development of 3D printable high-impact denture bases. Full article

Background/Objectives: This study investigates the chemical structure and molecular interactions in 3D-printed dental resins reinforced with varying concentrations of Yttria-Stabilized Zirconia (YSZ) nanoparticles, using Fourier-Transform Infrared Spectroscopy (FTIR) to assess the compatibility and bonding behavior at the molecular level. Methods: Three groups of 3D-printed methacrylate-based resin discs were fabricated: a control (0% YSZ), and experimental groups reinforced with 1% and 3% YSZ nanoparticles. Samples were produced using Digital Light Processing (DLP) technology and post-processed under standardized conditions. FTIR spectra were collected via ATR mode over a wavenumber range of 4000–600 cm⁻¹. Spectral differences at key wavenumbers (1721.16, 1237.11, and 929.62 cm⁻¹) were statistically analyzed using one-way ANOVA and Tukey’s post hoc test. Results: FTIR spectra showed no significant shifts in the ester carbonyl band at 1721.16 cm⁻¹, suggesting the preservation of the core resin matrix. However, a statistically significant increase in absorbance at 1237.11 cm⁻¹ was observed in the 1% YSZ group (p = 0.034), indicating dipolar interaction. A distinct new peak at 929.62 cm⁻¹, corresponding to Zr–O vibrations, emerged in the 3% YSZ group (p = 0.002), confirming successful nanoparticle integration. Conclusions: YSZ nanoparticles enhance specific molecular interactions within methacrylate-based dental resins without compromising structural integrity. These findings support the potential application of YSZ-reinforced 3D-printed resins in durable, biocompatible permanent dental restorations. Full article