Journal of Composites Science

Objectives: This systematic review and meta-analysis aimed to evaluate microbial adhesion and biofilm formation on additively manufactured composite-based orthodontic clear aligners compared with thermoformed aligners and other conventional polymeric materials. The influence of material composition, surface roughness, post-processing parameters, and cleaning protocols on microbial colonization was also assessed. Methods: A comprehensive search of PubMed, EMBASE, Scopus, Web of Science, and the Cochrane Library was conducted up to September 2025. Only in vitro studies investigating microbial adhesion, biofilm biomass, or microbiome changes on three-dimensional (3D)-printed aligner composites were included. Primary outcomes consisted of colony-forming units (CFU), optical density (OD) from crystal violet assays, viable microbial counts, and surface roughness. Risk of bias was assessed using the RoBDEMAT tool. Data were narratively synthesized, and a random-effects meta-analysis was performed for comparable datasets. Results: Five studies fulfilled the inclusion criteria, of which two in vitro studies were eligible for meta-analysis. Microbial adhesion and biofilm accumulation were influenced by the manufacturing technique, composite resin formulation, and surface characteristics. Certain additively manufactured aligners exhibited smoother surfaces and reduced bacterial adhesion compared with thermoformed controls, whereas others with increased surface roughness showed higher biofilm accumulation. Incorporating bioactive additives such as chitosan nanoparticles reduced Streptococcus mutans biofilm formation without compromising material properties. The meta-analysis, based on two in vitro studies, demonstrated higher OD values for bacterial biofilm on 3D-printed aligners compared with thermoformed aligners, indicating increased biofilm biomass (p < 0.05), but not necessarily viable bacterial load. Conclusions: Microbial adhesion and biofilm formation on 3D-printed composite clear aligners are governed by resin composition, additive manufacturing parameters, post-curing processes, and surface finishing. Although certain 3D-printed materials display antibacterial potential, the limited number of studies restricts the generalizability of these findings. Clinical Significance: Optimizing composite formulations for 3D printing, alongside careful post-curing and surface finishing, may help reduce microbial colonization. Further research is required before translating these findings into definitive clinical recommendations for clear aligner therapy. Full article