This study will compare the dimensional discrepancies of functional casts obtained using conventional custom trays and 3D-printed custom trays made from PET-G (Polyethylene Terephthalate Glycol) filament. Thirty completely edentulous maxillary patients treated in the Complete Denture Course at the School of Dentistry, University of São Paulo (FOUSP), will be evaluated. Anatomical casts will be obtained, digitized, and used to fabricate conventional or digitally designed and 3D-printed custom trays. Functional impressions will then be made with zinc-oxide eugenol impression paste, and the resulting functional casts will be fabricated in Type III gypsum. The casts will be digitized and compared using 3D metrology software. Measurements will be obtained at standardized anatomical regions, including the bilateral tuberosity regions, incisive papilla, palatine raphe, and four vestibular points.
Patients with stable systemic conditions.
Completely edentulous maxillary patients.
Residual ridges classified as normal according to Tamaki (1983).
Recent tooth extraction, defined as extraction within the previous 6 months.
High or severely resorbed residual ridges.
Single group
Conventional PMMA Custom Tray
Diagnostic testParticipants or casts associated with the conventional technique will be evaluated. The anatomical model will be delineated according to the FOUSP Complete Denture Course and isolated with a gypsum-resin separator. Chemically activated PMMA acrylic resin will be manipulated at a ratio of 15 cc powder to 5 cc liquid, adapted to the model in the plastic phase, and finished and polished after complete polymerization.
3D-Printed Custom Tray
Diagnostic testParticipants or casts associated with the printed technique will be evaluated. The custom tray will be digitally designed using inLab software with a thickness of 3 mm and zero spacing. The STL file will be printed on an Adventurer 4 Pro printer using CREALITY CR-PETG thermoplastic filament, according to the manufacturer's parameters. The tray will then be finished and polished.
Three-dimensional discrepancy between functional-cast STL meshes
Difference between the STL meshes of the functional casts obtained using conventional PMMA custom trays and the functional casts obtained using PET-G filament 3D-printed custom trays. Mesh discrepancy will be quantified in ZEISS Inspect software using standardized anatomical measurement points. The measurements will be performed using the deviation label tool (inspect\>deviation label) and collected in mm. The measurement locations will include the bilateral tuberosity regions, palatine raphe region, incisive papilla region, and four vestibular points.
Regional three-dimensional mesh discrepancy at standardized anatomical points
Regional differences between the STL meshes will be measured at eight standardized points: two points in the tuberosity regions, one point in the palatine raphe region, one point in the incisive papilla region, and four vestibular points.
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