Clinical evaluation of final impressions from three-dimensional printed custom trays.

This study aimed to evaluate the quality of the final impressions taken by three-dimensional printed custom trays for edentulous patients. Custom trays were designed with or without saddle-shaped tissue stops and fabricated by three-dimensional printing techniques. Manually made trays with photocurable materials were produced as controls. Both 3D printed custom trays and manually made ones were used to take impressions from edentulous patients. After 3D scanning of the final impression, the impression materials were removed, thus the underneath tray surfaces were able to be scanned, allowing the thickness of the impression materials to be measured. Final impressions obtained by pre-border-molded 3D printed trays were scanned as references, to which the flange extension deviations and morphology deviations of the impressions taken by both 3D printed trays and manually made ones were calculated. The results showed that (1) impressions from 3D printed custom trays had better thickness distribution than that of manually made ones; (2) impression morphology deviations in non-marginal area were neither statistic different between 3D printed trays and manually made trays, nor between trays with and without tissue stops; and (3) final impressions taken by custom trays without pre-border-molding were tended to have insufficient flange extensions.