The use of CAD/CAM systems for planning, design, and production in dentistry provides many benefits for both healthcare professionals and patients. However, the rapid implementation of such systems and associated materials makes it challenging to ensure that patients are treated with optimal oral devices in terms of biocompatibility [
28]. Research focusing on the safe use of CAD/CAM biomaterials is therefore vital.
Adverse reactions from biomaterials depend on the patient being exposed to components released from the biomaterial. It should be emphasized that the polymerization process from acrylic-based biomaterials never reaches completeness which facilitates the release of uncured leakage products from the materials regardless of the manufacturing technique. Such leakage products are commonly residual acrylate monomers and other chemical additives [
29]. The concentration of the leakage products mainly depends on factors such as polymerization type, polymerization time, and polymerization temperature [
30]. CAD/CAM production introduces processing variables that may affect the biocompatibility of the biomaterials [
31,
32]. The milling production has less processing variables compared to the printing counterpart since the material is pre-polymerized, and the post-processing only involves grinding and polishing. The acrylic-based milling blocks are produced under high temperature and pressure to optimize the polymerization process and achieve a higher DC [
33,
34]. However, long production time and material waste from ineffective use of the material block are drawbacks associated with milling. Printing overcomes most of these challenges, although more workflow parameters are imposed on the individual manufacturer of the dental device. The printing process entails the conversion of a liquid resin to a solid material: Different printing technologies, liquid resin chemistries, orientation of the print objects, and the print layer thickness are all sources of variation [
35‐
38]. Further, post-processing steps such as isopropyl rinse and different post-curing methods are variables to be aware of [
39]. In summary, high variation in the biocompatibility of printed devices may occur.
MTT cell viability
The MTT assay results showed a significant decrease in cell viability among several manufacturing techniques and workflows (Fig.
1) compared to unexposed controls. Nevertheless, all the materials tested showed above 70% cell viability at all extract dilutions. According to ISO 10993-5, a sample is considered to have a cytotoxic potential if the viability is reduced to less than 70% [
25]. It must be emphasized, however, that this viability threshold cannot decisively be regarded as proof for not being cytotoxic, i.e., lack of evidence on cytotoxic response is not evidence of the opposite. Although the MTT assay is widely used, the MTT results rely entirely on the assumption that mitochondrial dehydrogenase activity is constant in all viable cells. Even though this should be fulfilled, the assay cannot discriminate between cell death and cell growth inhibition [
40]. Also, cell viability results from monomer exposure have shown to be largely dependent on the cell model systems used [
41]. In addition, interlaboratory tests have shown that the ISO 10993-5 specifications set are not explicit enough to obtain comparable results for a medical device [
42]. In summary, misinterpretations, overshadowing of possible cytotoxic effects, and false conclusions could be the result. This also highlights the caution that must be taken when in vitro results are used in the translation to clinical settings. The conduction of additional biological assays is, therefore, highly recommended to support MTT results.
In our study, the Splint 2.0 material (DLP) post-cured with AF demonstrated a significant decrease in viability for all treatment groups. Reymus et al. [
10] observed that the choice of post-curing method had an impact on the DC of printed occlusal device materials concluding that specimens post-cured with OF achieved the highest DC. Assuming that cell viability is correlated with DC, this is in line with our results for the DLP workflow. While the AF unit facilitates constant curing from 4 × 9 W UV lamps, the OF curing unit irradiates with two xenon lamps (200 W in total) flashing at 10 Hz in a wide spectrum range (280–700 nm). In addition, the unit facilitates N
2 inert gas during post-curing to prevent the formation of an oxygen-inhibited layer [
43]. The presence of this layer on the surface of the material will reduce the DC [
44]. In clinical settings, higher levels of unpolymerized monomers, where the oxygen-inhibited layer was present, have also been reported [
45]. Post-processing by grinding and polishing is effective in the removal of this unpolymerized layer [
46], however, grinding and polishing of the interior parts of resin-based occlusal devices is contraindicated as this may affect the fitting of the device. In this respect, it has been reported significantly higher MMA concentrations in the salivary film on the fitting side of acrylic orthodontic appliances compared to whole saliva samples highlighting the clinical relevance of this issue [
47]. In our study design, the specimens were ground and polished on all sides removing the inhibition layer. This ideal condition may facilitate possible underestimation of leakage products relative to clinical settings.
A reduction in cell viability at higher extract concentrations is evident for the Dental LT Clear material (SLA). No clear difference in cell viability is shown when comparing the OF and FC workflows. The FC unit irradiates with 13 LEDs giving a total of 39 W output. The LEDs emit close to UV (405 nm) which has the benefit of curing thicker parts more efficiently than light sources of lower wavelengths [
48]. Although our study design cannot specifically evaluate the effect of temperature, elevated post-curing temperatures from the FC unit may increase reaction kinetics facilitating greater access of monomers to growing polymer chains. In other studies, the effect of increased post-curing temperature on acrylic-based resins has demonstrated an improvement in mechanical properties, degree of conversion, and biocompatibility [
49,
50]. In a study by Jung-Hwa et al. [
51] they found that increased temperature in combination with oxygen shielding (inert gas or glycerol) enhanced both the mechanical properties and the DC of acrylic-based prints.
The PMMA-based material for milling is assumed to be highly polymerized. However, the MTT results showed reduced cell viability in an extract concentration-dependent manner. In a study by Bürgers et al. [
52], the measured cytotoxicity of the same material presented different cell viability results depending on the applied cell line, but the cell viability was not below 70%. Similarly, a slight cytotoxic effect was shown for PMMA interim material blocks [
53]. The reduction in cell viability may be explained by the elution of other resin matrix additives (initiators, inhibitors, accelerators, plasticizers, etc.), however, this was not evaluated in our study.
The analyses of the autopolymerized material stored for one hour in dH
2O showed a significant decrease in cell viability. In contrast, no viability loss was observed in the analyses of material stored for 12 h in dH
2O. Up to 24 h of water storage has been suggested to be a standard procedure for all autopolymerized acrylic-based appliances before insertion into the patient´s mouth [
47]. A study by Na-Eun [
54] showed that immersing printed resins in 100 °C water for 5 min increased cytocompatibility and the DC. Although storing print objects in water as a post-processing procedure is not declared for any of the CAD/CAM materials, this might be beneficial in terms of material biocompatibility.
Levels of cytoprotective proteins
To further assess possible cytotoxic responses, protein expression analysis was performed by standard Western blot immunoassay. Based on previous studies of HEMA-exposed cells [
26,
55], five proteins (HO-1, Pirin, NQO-1, p62, and GCLC) were chosen. The proteins are vastly associated with cellular stress response and an up-regulation of the proteins can be interpreted as increased demand for cytoprotection. Becher et al. [
26] used microarray to quantify RNA transcripts of the 25 most up-regulated genes when a BEAS-2B cell line was exposed to 2-hydroxyethyl methacrylate (HEMA). They found that HO-1 was most upregulated (4,44-fold change). In contrast, our study on PJ49 cells did not detect HO-1 from any of the exposure scenarios.
The Splint 2.0 material (DLP) showed a trend in the upregulation of the proteins GCLC, NQO1, and p62 in a concentration-dependent manner, although not significant. However, experiments using specimens post-cured with AF depicted a higher trend in the upregulation of the proteins compared to those post-cured with OF. This may support a higher DC in the materials post-cured with OF as upregulation of the proteins can be linked to increased release of electrophilic monomers [
55]. Exposure to electrophilic monomers have previously been shown to cause GSH depletion and increased levels of oxidative stress [
56]. Increased levels of GCLC and NQO1 can be a response to such events. The p62 protein is associated with autophagy. Increased autophagy improves cellular stress resistance since autophagy decreases metabolic load and toxicity by removing damaged cellular components [
57]. Also, the cells exposed to Dental LT Clear (STL) extract showed upregulation of the cytoprotective proteins in a concentration-dependent manner, although not as prominent as the DLP workflow. Samuelsen et al. [
55] observed an upregulation of Pirin in THP-1 cells exposed to 2 mM HEMA. In our study, we could not see any changes in Pirin levels regarding the print workflows.
Although the PMMA milling material showed some degree of cell viability reduction, no alterations in relative protein expression compared to the control were shown for the selected proteins at 100% extract concentration. Assuming that methacrylates in general activate the Nrf2 pathway, our results indicate that other leakage products are responsible for the observed viability loss. A study designed to determine such leakage products could potentially verify this hypothesis.
Exposure to autopolymerization extracts showed that specimens stored in dH2O for 12 h demonstrated a decrease in expression of Nrf2-associated proteins compared to 1-hour dH2O storage. Among all the workflows, Pirin is only significantly increased in the 1-hour dH2O storage group. Since the autopolymerization material is comprised mainly of MMA it might be assumed that MMA exposure to the cells increases Pirin expression. However, this can only be determined by analytical methods aiming to quantify and identify specific monomers or additives.
Much is known about the role of Nrf2 in detoxification and response to stress, however, the evidence on how Nrf2 regulates immune cell functions is less understood [
58]. Nrf2 is believed to play a protective role in contact dermatitis by upregulation of antioxidant and cytoprotective genes. Increased mRNA levels of NQO1 and HO-1 have been reported in response to several contact sensitizers in dendritic cells and THP-1 monocytic cells [
59]. Nrf2 has also been demonstrated to recruit neutrophils in contact hypersensitivity [
60]. In the same study, they compared knock-out mice with wild-type mice and found an upregulation of Nrf2 antioxidant genes (HO-1, GCLC, and NQO1) supporting Nrf2´s critical role in skin hypersensitivity. In line with this, Nrf2 activity is used as a measure of sensitizing potential [
61]. Hence, our results may indicate that printed acrylic-based materials, giving a higher upregulation of Nrf2-associated proteins, could result in a higher sensitization potential than milled acrylic-based materials. Also, water storage of acrylic-based dental devices for 12–24 h seems beneficial to reduce exposure to material leakage products. This may also reduce the possible risk of sensitization reactions from such leakage products.
This study has investigated the effect of some selected workflow variables. In printing, several other post-processing variables can potentially influence biocompatibility. Parameters such as printing orientation, print layer thickness, and rinsing solvents are some other parameters that could be more specifically considered in future studies. Grymak et al. [
62] investigated the hardness and polishability of different occlusal device materials. They found that printed specimens treated with the same polishing protocol differed both in surface roughness and hardness depending on the chosen print angle. Such variations in surface characteristics may affect the in vitro biocompatibility of occlusal device materials. Although all specimens were visually confirmed in our study, only minor deviations between parallel specimens were shown in the MTT assay suggesting consistent results with the applied grinding and polishing protocol. In addition, using SiC paper discs for grinding and polishing is used for standardization purposes which deviates from clinical settings were tungsten carbide burs, rubber or cotton wheels with high gloss polishing paste are used. There is always a risk of contamining the materials from such procedures, while heat generated from high gloss polishing without water cooling might alter surface characteristics of the specimens. Such factors could have affected the source of variation when conducting the following biological assays in the current study. Other variables may also alter surface characteristics in a clinical setting. Greil et al. [
63] demonstrated increased water sorption of printed denture base materials compared to other manufacturing techniques. Water sorption causes swelling and a decrease in hardness of the material which may further increase material abrasion accelerating the release of wear particles and leakage products.
Lastly, with emerging technologies and a rapid introduction to novel dental materials, a demand for more informative and accurate safety data sheets regarding the content of the materials should be encouraged. This will provide both the scientific society in the biomaterial field as well as the health profession with a better foundation in decisions on material biocompatibility and patient safety-related issues.