Different techniques have been used to construct provisional crowns to protect prepared teeth. The purpose of this in vitro study was to assess the internal fit and marginal discrepancy of provisional crowns made by different methods. A total of 48 provisional crowns were constructed and divided into three groups (n
= 16) according to the fabrication methods: fabricated manually-group MAN; computer-aided design/computer aided manufacturing technology-group CAM; and 3-dimensional (3D)-printed technology-group 3DP. The same standard tessellation language (STL) file was used for both CAD/CAM and 3D-printed group. The silicone-checked method was used to measure the internal gap distance. The marginal discrepancy was measured by using the polyvinyl siloxane (PVS) replica method and swept-source optical coherence tomography (OCT) scanning technique. Data were analyzed with one-way analysis of variance (ANOVA) nonparametric Kruskal-Wallis and Tukey tests at α = 0.05. At the central pit and axial walls, the gap distance mean values of group CAM were higher than those from group MAN and 3DP. The group 3DP was statistically significantly higher in gap distance at the location of occlusion than group MAN and group CAM (p
< 0.05). The total gap distances assessed by silicone-checked method revealed there were no statistically significant differences between the tested groups (p
> 0.05). The total mean values of absolute and horizontal marginal discrepancy of the group 3DP obtained by using the PVS-replica method and OCT scanning technique were significantly higher than the group MAN and CAM (p
< 0.05). Regression correlation results of marginal discrepancy indicated a positive correlation (r
= 0.902) between PVS-replica method and OCT scanning technique. The manually fabricated provisional crowns presented better internal fit and a smaller marginal discrepancy. Between different assessment techniques for marginal adaptation, PVS-replica method and OCT scanning technique have a positive correlation.
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