3D Printing of Customized Dental Appliances: A Comprehensive Review

Abstract

AbstractThree dimensional (3D) printing, also known as additive manufacturing, has rapidly emerged as one of the most influential innovations in modern dentistry. By enabling the fabrication of highly accurate and patient specific dental appliances through digital workflows, 3D printing has significantly improved treatment precision, efficiency, and patient comfort. Traditional methods of appliance fabrication often involve multiple clinical and laboratory steps that are time consuming and susceptible to inaccuracies. In contrast, digital technologies such as intraoral scanning, computer-aided design (CAD), and computer-aided manufacturing (CAM) allow clinicians to design and produce customised dental appliances with enhanced accuracy and reduced turnaround time.The applications of 3D printing in dentistry have expanded across various specialties, including orthodontics, prosthodontics, implantology, and paediatric dentistry. Customised appliances such as orthodontic aligners, retainers, surgical guides, space maintainers, occlusal splints, and dentures can now be fabricated using additive manufacturing techniques. These developments are particularly beneficial in paediatric dentistry, where appliances must be carefully tailored to accommodate the unique anatomical and behavioural needs of growing children.This review discusses the evolution of 3D printing in dentistry, the materials and technologies involved, the digital workflow used for appliance fabrication, and the expanding clinical applications of customised dental appliances. Additionally, the advantages and limitations of this technology are explored to highlight its growing significance in patient-centred dental care.