Microleakage of chairside moulded, 3D-printed and milled provisional restorations using a curve-fit approach.

The purpose of this study was to evaluate and measure the microleakage inhibiting quality of provisional restorations manufactured using computer-aided manufacturing, 3D printing, and chairside molded provisional restorative materials. Fifteen provisional restorations each from 3D printed, milled, and chairside molded were manufactured. All restorations were cemented onto sintered zirconia abutment dies and adhered with zinc-oxide non-eugenol temporary cement. Artificial aging was conducted by thermocycling for 800 cycles to simulate 1 month of clinical use. All specimens were submerged in 2% (w/w) methylene blue for 24 hours at 37°C, sectioned, and analyzed digitally for the distance of dye penetration through image analysis. The data were analyzed using the Kruskal-Wallis test with Dunn-Bonferroni post-hoc. Significant differences in dye penetration depth were observed between all groups except milled vs chairside molded. Light microscopy revealed differences in mean cement thickness for 3D printed, milled, and chairside molded of 83.6 µm (1σ = 31.9 µm), 149.1 µm (1σ = 88.7 µm) and 137.9 µm (1σ = 67.2 µm) respectively. Conclusion: 3D printed provisional restorations were found to have the least amount of microleakage compared to milled and chairside molded provisional restorations.