This study aims to evaluate the wear resistance and muscular efficiency of denture teeth fabricated using two different methods: 3D printing and conventional techniques. The research is designed as a crossover in vivo study, where completely edentulous patients will receive both types of dentures sequentially. The primary outcome is the amount of wear observed in the denture teeth over time, while the secondary outcome is the muscular efficiency measured using electromyography (EMG). The study seeks to determine whether 3D printed denture teeth offer advantages in durability and functionality compared to conventionally fabricated denture teeth. Results from this study may provide valuable insights into improving the quality and comfort of dentures for edentulous patients.

Complete dentures are a common treatment option for edentulous patients, providing essential functionality and aesthetics. With advancements in digital dentistry, 3D printing has emerged as a promising technique for fabricating denture teeth, offering potential benefits such as customization, faster production, and improved material properties. However, the long-term performance of 3D printed denture teeth compared to conventionally fabricated teeth remains under investigation.

This study is designed to assess two critical aspects of denture teeth performance: wear resistance and muscular efficiency. Wear resistance refers to the ability of denture teeth to withstand forces during chewing without significant degradation, while muscular efficiency evaluates how effectively the jaw muscles function with the dentures during activities like chewing and speaking.

The study will recruit completely edentulous patients aged 21-70 years from the Prosthodontics Department at Cairo University. Participants will receive two sets of complete dentures: one fabricated using conventional techniques and the other using 3D printing. The crossover design allows for direct comparison within the same group of patients, minimizing individual variability.

Primary impressions will be taken, followed by the fabrication of dentures using standardized protocols. The amount of wear will be measured by scanning the denture teeth at delivery and after three months of use. Muscular efficiency will be assessed using electromyography (EMG) to measure bite force at delivery and after three months.

This study is self-funded and conducted under the supervision of the Prosthodontics Department at Cairo University. Ethical approval has been obtained, and all participants will provide informed consent. The findings of this study are expected to contribute to the advancement of prosthodontic practices, offering evidence-based recommendations for the use of 3D printed denture teeth in clinical settings.

Inclusion Criteria:

Completely edentulous patients. Aged 21-70 years old. Able to read and sign the informed consent document. Class Ι maxilla-mandibular relationship. Free from temporomandibular disorders. Free from systemic diseases that could affect neuromuscular behaviors or muscular activities.

Edentulous condition falls within Class I and II cases based on the Prosthodontic Diagnostic Index (PDI) classification system for complete edentulism.

Exclusion Criteria:

Presence of major medical problems or severe chronic diseases. Poor residual ridge anatomy. Any intra-oral soft or hard tissue abnormalities. Flat, flabby, or knife-edge ridge anatomy.

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De-identified individual participant data related to primary and secondary outcomes (amount of wear and muscular efficiency).

Supporting documentation such as study protocol, statistical analysis plan, and informed consent form.

IPD and supporting information will be available 6 months after study completion and will remain accessible for 5 years.

Access will be granted to qualified researchers affiliated with academic institutions or research organizations.

Researchers must submit a formal request and provide a detailed research proposal outlining the intended use of the data.

Data will be shared via secure platforms or repositories, ensuring confidentiality and compliance with ethical guidelines.