Effect of post-processing on the surface, optical, mechanical, and dimensional properties of 3D-printed orthodontic clear retainers

Objectives: To address the high surface roughness and poor optical properties of three-dimensional (3D) printed orthodontic clear retainers, an alternative post-processing protocol was investigated with the goal of achieving improved surface, optical, and mechanical properties while preserving dimensional accuracy. Materials and methods: Samples were prepared from two biocompatible methacrylate-based 3D-printing resins (Formlabs Dental LT Clear V2, NextDent OrthoFlex) and one thermoplastic material (Duran). For the 3D-printed resins, one group was post-processed by rinsing in isopropyl alcohol, while another group was centrifuged before post-curing in glycerine. Three different testing conditions were used: dry, wet (24-h water immersion), and aged (thermocycling for 10,000 cycles). Surface characteristics were evaluated qualitatively and quantitatively. Optical properties were assessed for transparency and colour stability, while mechanical properties were elicited from tensile and microhardness tests. Water sorption and solubility were calculated. Samples mounted on a dental model were scanned by micro-computed tomography to measure thickness and gap width. Results: 3D-printed samples post-processed by centrifugation showed significantly decreased surface roughness and improved visible light transmission, colour stability, tensile strength, and hardness. The centrifuged samples showed significantly increased thickness, while designing an offset equal to this thickness improved the adaptation. Conclusions: Post-processing by centrifugation produces surface coating that enhances the surface and optical properties of the 3D-printed orthodontic retainers, while curing in an oxygen-free environment improves their mechanical properties. Design modifications may be necessary for this protocol to ensure proper adaptation to the dentition. Clinical relevance: Proper design and post-processing protocols are necessary to achieve the desired properties of orthodontic clear retainers.