Background: Additive manufacturing has emerged as a promising technique for fabricating complete dentures, yet the influence of printing parameters- particularly build orientation- on surface quality and color stability remains insufficiently understood.
Purpose: This study aimed to evaluate the effect of three different 3D printing build orientations (0°, 45°, and 90°) on the surface roughness and color stability of removable complete dentures, with the goal of identifying the optimal configuration for clinical application.
Materials and Method: Complete denture bases and artificial teeth were fabricated separately using a 3D printer and subsequently assembled. A total of 90 specimens were fabricated and printed at 0°, 45°, and 90° build orientations (n=10 per subgroup). Surface roughness was measured using a profilometer, and color stability was assessed by spectrophotometric analysis after immersion in commonly encountered staining solutions under simulated oral conditions over time.
Results: Build orientation significantly affected both surface and optical properties of the specimens. The 45° orientation exhibited the highest surface roughness values, whereas the 0° orientation produced the smoothest surfaces. Color evaluation revealed that dentures printed at 90° orientation underwent the greatest discoloration, while those printed at 0° maintained superior color stability throughout the observation period.
Conclusion: Build orientation plays a pivotal role in the long-term esthetic and functional performance of 3D-printed complete dentures. Printing at 0° orientation provides smoother surfaces and improved resistance to discoloration, suggesting it as the most favorable configuration for clinical use. Optimizing printing parameters is essential for enhancing the durability, hygiene, and esthetics of dentures fabricated via additive manufacturing.