Clinical Performance and Fit of 3D-Printed Versus Milled Endocrowns: An 18-Month Trial

Eligible participants will be recruited from the Conservative Dentistry Department, Faculty of Dentistry, October 6 University.

Following confirmation of satisfactory root canal treatment. Tooth preparation will follow standardized endocrown guidelines. All preparations will be performed by a single calibrated operator (Y.A.E.).

Full-arch digital impressions will be captured using an intraoral scanner, including scans of the prepared tooth, opposing arch, and bite registration. Digital files (STL format) will be used to design definitive restorations in CAD software. Following digital design, participants will be randomly allocated (1:1 ratio) to one of two fabrication groups:

Group 1 (Intervention): Additive manufacturing (3D-printed resin composite) Group 2 (Comparator): Subtractive manufacturing (milled resin composite) Teeth will be temporized with intermediate restorative material, then temporary materials will be removed and preparations cleaned. Restorations will be tried to verify fit, contacts, and occlusion.

After cementation, scan the seated restoration with the same intraoral scanner to create baseline restoration STL file (T0) for longitudinal fit assessment. Participants will be recalled at baseline (T0), 6 months (T1), 12 months (T2) and18 months (T3). At each visit, restorations will be evaluated using Modified FDI criteria (clinical performance) and 3D digital superimposition (Restoration fit via Geomagic Control X)

Inclusion criteria

• Patient-Related Criteria

• Age: Between 20 and 40 years.
• Oral Hygiene: Good oral hygiene, evidenced by low plaque and gingival index scores.
• Willingness to attend regular follow-up visits during the study period

• Tooth-Related Criteria
• Endodontic Quality: High-quality root canal treatment with no clinical or radiographic signs of pathology.
• Tooth Type: A permanent molar tooth requiring an endocrown after successful root canal treatment.
• Located in functional occlusion and opposing natural teeth in stable occlusal contact with the restored tooth.
• Teeth free from cracks, fractures, or internal resorption; supporting tissues without structural defects that may compromise restoration success

Exclusion criteria

• Patient-Related Criteria

• Parafunctional Habits: Severe bruxism, clenching, or other parafunctional habits.
• Allergies: to any study materials (e.g., resin composites, bonding agents).
• Patients with systemic diseases contraindicate elective dental treatment (e.g., uncontrolled diabetes)

• Tooth-Related Criteria
• Insufficient Tooth Structure: Less than 2mm of circumferential sound denting height or deep, unrestorable.
• Tooth opposes prosthetic restoration.
• Teeth with a history of fixed prosthetic restorations (previous crowns, inlays/onlays, or bridge restorations)
• Periodontal Issues: Active periodontal disease, excessive mobility (> Grade 1, or a hopeless long-term prognosis.