Enhancing Fixed Partial Denture Pontic Fabrication: An In Vitro Comparative Study of the Digital and Manual Techniques.

Background Advancements in computer-aided design (CAD) and computer-aided manufacturing (CAM) technology have significantly improved the accuracy and consistency of producing fixed partial dentures (FPDs) compared to traditional manual methods. However, the fully digital transfer of mock-up morphology to final FPDs is not yet fully explored. Proper pontic design, which avoids direct gingival contact, is essential for maintaining oral hygiene and preventing tissue irritation. Aim and objectives This study aims to compare the effectiveness of digital versus manual methods in FPD pontic fabrication, focusing on the trueness of digitally fabricated FPD patterns. Key objectives include assessing thickness, vertical gaps, and anatomical accuracy to determine the advantages of CAD-CAM technologies over traditional techniques. Materials and methods In this in vitro study, a total of 45 FPD pontics were fabricated and divided into three groups (15 each): digitally fabricated (using CAD software and CAM systems), manually fabricated (using traditional wax-up techniques), and a control group (typodont teeth). Tooth preparation was performed on a typodont, and impressions were taken to create casts. One cast was scanned and digitally designed, while the other was used for manual fabrication. Outcome assessments included vertical gap measurement using a stereo microscope, thickness evaluation with a digital caliper, and anatomical similarity assessment by independent evaluators. Statistical analysis involved one-way analysis of variance (ANOVA), post hoc Tukey's analysis, and unpaired t-tests using SPSS software version 26.0 (IBM Inc., Armonk, New York). Statistical significance was set at 0.05. Results The digital group exhibited lower mean thickness at the incisal (1.92±0.130 mm vs. 2.46±0.219 mm for manual, p=0.000), middle (7.00±0.223 mm vs. 8.88±0.983 mm for manual, p=0.001), and cervical sites (9.06±0.134 mm vs. 10.08±0.454 mm for manual, p=0.000). No significant differences were found between the digital and control groups. No significant differences were observed between digital, manual, and control groups at any site (p=0.688 to 0.997). The digital group demonstrated superior accuracy and consistency compared to the control group (mean value of 1.00±0.00 vs. 2.93±0.798, p=0.000). Conclusion CAD-CAM technology greatly improves the precision and consistency of FPD pontic fabrication compared to traditional manual techniques. Digital methods produce thinner pontics with superior anatomical accuracy, although vertical gap measurements are similar across methods. These findings emphasize the benefits of CAD-CAM in enhancing prosthetic outcomes and suggest potential improvements in clinical practices for prosthodontic rehabilitation.