Clinical evaluation of a one‐piece polyetheretherketone removable partial denture fabricated using a novel digital workflow: A self‐controlled clinical trial

Abstract Purpose To explore the clinical application of one‐piece polyetheretherketone (PEEK) removable partial dentures (RPDs) fabricated using a novel digital workflow and to evaluate their weights and fits in vivo and patient satisfaction. Materials and Methods Fifteen cases with posterior partially edentulous situations were selected, and each patient received two types of RPDs, including a novel digital workflow (test group) and a conventional workflow (control group). For the test group, one‐piece RPDs were designed through three‐dimensional (3D) methods by scanning stone casts and fabricated by milling PEEK discs. Each RPD was weighed. The gaps between the oral tissue and RPDs in each group were duplicated using a polyvinylsiloxane (PVS) replica and measured by 3D analysis. A visual analog scale (VAS) was used to evaluate the patient's satisfaction. Paired t ‐tests were used to compare the differences in the weight, the gaps of each RPD, and VAS values between the two groups. One‐way analysis of variance tests was used to compare the differences in the gap among different components in each group. Results The RPD in the test group weighed less than that in the control group ( p < 0.01). No statistically significant differences in the gaps of denture bases and rests ( p > 0.05) were found between the two groups, but the gaps of major connectors in the test group were significantly smaller than in the control group ( p < 0.05). The VAS scores for comfortableness and masticatory efficiency were not significantly different between the two groups ( p > 0.05) but the scores for the aesthetic appearance of the clasps in the test group were significantly higher than that in the control group ( p < 0.05). Conclusions One‐piece PEEK RPDs manufactured using a novel digital workflow weighed less than conventional RPDs and exhibited a clinically acceptable internal fit. Although the aesthetic appearance of the PEEK clasps was superior to the control, there is still room for improvement.