Additive Manufacturing of Dental Prosthetics: A Comprehensive ‎Review of ‎Accuracy, Mechanical Properties, and Clinical ‎Feasibility

Purpose: The present review aims to critically evaluate the dimensional accuracy, mechanical ‎integrity, and clinical applicability of three-dimensional (3D)-printed dental prosthetics in ‎comparison with conventional subtractive manufacturing techniques‎.

Materials and Methods: A systematic analysis of recent in vitro and clinical studies (2021–2026) was conducted, ‎focusing on stereolithography (SLA), digital light processing (DLP), and selective laser ‎melting (SLM) technologies. Parameters assessed included marginal and internal fit ‎accuracy, flexural strength, surface hardness, and long-term aging behavior under ‎thermocycling and water storage conditions‎.

Results: ‎3D-printed crowns demonstrated superior marginal fit (14 ± 5 μm) compared to milled ‎counterparts (22 ± 4 μm), with statistically significant differences (p ≤ 0.022). Nanoparticle-‎reinforced 3D-printed resins achieved flexural strengths ranging from 80.02 to 114.60 MPa, ‎exceeding ISO 20795-1 requirements (65 MPa). SLA technology consistently outperformed ‎DLP in dimensional trueness, particularly for complex multi-unit fixed partial dentures. ‎However, 3D-printed zirconia exhibited greater variability in mechanical properties due to ‎porosity and processing parameters, though clinically acceptable values were achieved with ‎optimized build orientations‎.

Conclusion: Additive manufacturing represents a transformative paradigm in prosthetic dentistry, ‎offering enhanced fitting precision, material efficiency, and workflow streamlining. While ‎milled zirconia remains the benchmark for predictability, advances in resin formulations, ‎nanoparticle reinforcement, and post-polymerization protocols position 3D printing as a ‎viable and increasingly preferred alternative for definitive dental restorations‎. (Open J Biomed Res 2026;5:34-42)