Effect of layer thickness and polishing on wear resistance of additively manufactured occlusal splints

Abstract

Objective: To evaluate the effect of polishing and layering thickness on the wear resistance of 3D-printed occlusal splint materials. Methods: Specimens with 3 different layer thicknesses (50, 75, 100 µm) were produced in the form of a disc 3 mm thick using V-Print splint resin on a 3D-printer with digital light processing technology. (n = 16 for each thickness) All specimens were washed and cured according to the manufacturer\"s instructions. Half of the specimens of each layer thickness were polished with silicon carbide papers. All specimens were subjected to 120.000 cycles of a chewing simulator for 2-body wear tests. Before and after the wear test, the specimens were scanned with a laser scanner, and the images were overlaid using a 3D analysis program and the volume loss was calculated. The wear patterns of the specimens were examined under a scanning electron microscope. Statistical evaluation was performed using a Shapiro-Wilk test, 2-way ANOVA, 1-way ANOVA, and Tukey post hoc test (α = 0.05). Results: While polishing had a significant effect (p = 0.003) on the wear volume of the occlusal splints, layer thickness (p = 0.105) and their interaction between polishing and layer thickness (p = 0.620) did not significantly affect the wear volume. Regardless of the polishing, the lowest mean wear was observed for D50 (0.064 mm3), followed by D75 (0.078 mm3), and D100 (0.096 mm3). However, a significant difference was observed only between polished D50 and unpolished D100. Conclusion: The polished 3D-printed occlusal splint resin showed higher wear resistance than the unpolished one, regardless of the layer thickness. Clinical significance: Since different layer thicknesses of 50 µm and greater had no effect on the wear resistance of the material, a layer thickness of 100 µm may be preferred for faster printing. However, polishing occlusal splints may reduce the amount of wear and improve clinical performance.