Accuracy of metal 3D printed frameworks for removable partial dentures evaluated by digital superimposition

To evaluate the accuracy of metal 3D printed frameworks (MEP group) for removable partial dentures (RPDs) by digital superimposition, in comparison to that of frameworks produced by the conventional (CON group) and resin printing/casting (RPC group) workflows.A partially edentulous maxillary dentiform was prepared with rest seats and guiding planes on the right canine, left first premolar, and left second molar. Thirty master casts were prepared via repeated impressions of the dentiform. Frameworks were fabricated by three different workflows (n = 10 for each group). The internal discrepancies of the frameworks were assessed at 12 points by digital scanning with an optical triangulation principle-based tabletop scanner and superimposition using a reference best-fit alignment method. First, the master cast was scanned alone. Subsequently, a thin silicone material was applied to the framework and fitted onto the master cast, after which the framework was removed. Finally, the master cast with the silicone material attached was rescanned. The data from the two scans were matched, with the reference being the area not occupied by the silicone.For the CON, MEP, and RPC groups, respectively, the mean overall internal discrepancies (279.72 µm, 241.02 µm, and 331.70 µm), and the mean internal discrepancies on palate areas (292.92 µm, 250.72 µm, and 355.84 µm) and rest seat areas (240.12 µm, 211.91 µm, and 259.26 µm) did not significantly differ among the three fabrication methods (p = 0.558, 0.542, and 0.774).The reference best-fit alignment of scan datasets is a useful approach to evaluate the internal discrepancy of frameworks. Metal 3D printing produces RPD frameworks that are comparable to conventional frameworks and meet clinical standards.