Comparative Analysis of the Structural Integrity and Dimensional Stability of Additively Manufactured Biopolymers vs. Thermoformed PETG: A 1-Year Retrospective Study on Polymer Performance in Orthodontic Applications

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Year : 2026 | Volume : 14 | 03 | Page :
    By

    Sujitha Suresh,

  • Remmiya Mary Varghese,

  • Parthiban saketharaman,

  • Mounica Dommeti,

  • V S Kumar Bhagavathula,

  • Gadde Harika,

  1. Undergraduate student, Saveetha Dental College and Hospitals, Saveetha Institute of medical and technical sciences, Saveetha university, Chennai, Tamil Nadu, India
  2. Associate Professor, Department of Orthodontics, Saveetha Dental College and Hospitals, Saveetha Institute of medical and technical Sciences, Saveetha university, Chennai, Tamil Nadu, India
  3. Professor, Department of periodontics, sri venkateswaraa dental College Ariyur, Pondicherry, India
  4. Private practitioner, Department of Orthodontics and dentofacial Orthopedics, Chennai, Tamil Nadu, India
  5. Senior Lecturer, Department of Oral and Maxillofacial Surgery, Konaseema institute of Dental sciences, Andhra Pradesh, India
  6. Assistant Professor, Department of Orthodontics and Dentofacial Orthopedics, SIBAR Institute of dental sciences, Guntur, Andhra Pradesh, India

Abstract

Objective: This study aimed to evaluate the long-term dimensional accuracy and structural performance of direct 3D-printed biopolymers compared to conventional vacuum-formed Polyethylene Terephthalate Glycol (PETG) composites. The investigation focused on how different polymer processing methods (additive manufacturing vs. thermoforming) influence material thinning and resistance to occlusal stress.

Methods: A retrospective analysis was conducted on 60 cases (n = 60) of post-orthodontic maintenance. The sample was divided into two cohorts: Group A (n = 30), utilizing additively manufactured (3D-printed) biopolymer retainers (0.75 mm); and Group B (n = 30), utilizing vacuum-formed PETG (0.75 mm). Polymer stability was quantified at two time points (T_0 and T_1) using digital surface mapping to measure changes in arch dimensions (inter-canine and inter-molar width). Material degradation and internal stress manifestations (thinning and micro-fractures) were assessed via high-resolution intraoral imaging and clinical structural audits.

Results: Preliminary data indicate that while both polymer systems provided sufficient arch stability, Group A demonstrated superior dimensional consistency in the posterior segment (P 0.05), confirming equal functional efficacy despite differing physical properties.

Conclusions: Both 3D-printed biopolymers and PETG composites are effective for 1-year orthodontic retention. However, additive manufacturing provides enhanced structural integrity by bypassing the thermal degradation and mechanical thinning inherent in traditional thermoforming. This study verifies that designer polymer architectures created via 3D printing offer superior performance in high-wear biomedical applications.

Keywords: Biopolym. Eng, Polyethylene Terephthalate Glycol (PETG), Additive Manufacturing, Struct. Composites, Polym. Processing, Biomaterials.

How to cite this article:
Sujitha Suresh, Remmiya Mary Varghese, Parthiban saketharaman, Mounica Dommeti, V S Kumar Bhagavathula, Gadde Harika. Comparative Analysis of the Structural Integrity and Dimensional Stability of Additively Manufactured Biopolymers vs. Thermoformed PETG: A 1-Year Retrospective Study on Polymer Performance in Orthodontic Applications. Journal of Polymer & Composites. 2026; 14(03):-.
How to cite this URL:
Sujitha Suresh, Remmiya Mary Varghese, Parthiban saketharaman, Mounica Dommeti, V S Kumar Bhagavathula, Gadde Harika. Comparative Analysis of the Structural Integrity and Dimensional Stability of Additively Manufactured Biopolymers vs. Thermoformed PETG: A 1-Year Retrospective Study on Polymer Performance in Orthodontic Applications. Journal of Polymer & Composites. 2026; 14(03):-. Available from: https://journals.stmjournals.com/jopc/article=2026/view=243453


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Ahead of Print Subscription Review Article
Volume 14
03
Received 23/04/2026
Accepted 08/05/2026
Published 11/05/2026
Publication Time 18 Days
33

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