Evaluation of a novel 3D-printed custom tray for the impressions of edentulous jaws

The purpose of this study was to evaluate a novel 3D-printed custom tray for impressions of edentulous jaws, and to compare it with conventional impression trays.Fifteen edentulous patients were enroled to evaluate the accuracy and border extension of a novel custom tray in the shape of a complete denture. Four impressions were made for each patient. Impressions made using novel custom trays were considered the experimental group, impressions made using conventional custom trays were considered the control group, and impressions made using final dentures and non-pressure custom trays were considered the reference groups. The experimental and control groups were compared with the reference groups using three-dimensional (3D) comparison analysis, and the impressions were further divided into regions. The root mean square (RMS) value was calculated to analyse the differences in impression morphology. Additionally, the experimental and control groups were compared to analyse border extension at standard locations.Compared to the final denture impression as a reference, the diagnostic denture impression (RMS:0.146 ± 0.024 mm) was closer to the reference than the conventional impression (RMS:0.176 ± 0.047 mm), with a significant difference only in the secondary stress-bearing area. The border extension of the diagnostic denture impression was slightly longer than the conventional impression; however, the difference was not statistically significant.The impressions made using the novel custom tray were similar to those made with a definitive complete denture. However, no significant differences were noted when compared with the conventional impressions.