Objectives To evaluate the wear resistance of three 3D-printed dental crown materials (NextDent C&B MFH, Saremco print CROWNTEC and Bego VarseoSmile Crown) under two environmental conditions (dry and artificial saliva), two loads (49N and 70N) and two surface treatments (polished and glazed).

Methods A total of 120 samples were divided into 24 groups and tested for wear under two loads (49N and 70N), surface treatment (polished or glazed), and environment (dry or submerged in artificial saliva). All samples underwent reciprocating wear testing at 1Hz using a wear simulator, replicating 48 months of In Vivo conditions with a stainless-steel ball as the antagonist. The coefficient of friction (CoF), surface roughness, volumetric and vertical wear loss were measured and statistically analysed. Confocal microscopy assessed the surface properties of crown materials and the antagonists.

Results The NextDent material demonstrated the most homogenous wear, with relatively low vertical and volumetric loss across all groups (p < 0.004). NextDent and Bego materials performed similarly in artificial saliva regardless of the load type (p > 1.000). The CoF remained below 0.3 for all groups. All groups exhibited significant increases in surface roughness after testing, however, this did not correlate with an increase in the CoF. Confocal analysis revealed material deformities due to load and notable scratch marks on the stainless-steel antagonists.

Conclusion It was found that all investigated 3D-printed materials can be suggested for provisional use. Both vertical loss and volumetric loss results should be included for material evaluation. CoF and surface roughness should be implemented into wear evaluation.

Clinical significance This study highlights the practical value of 3D-printed dental crown materials, particularly for provisional restorations. However, their extended use requires careful consideration of individual patient needs, emphasising the need for judicious clinical application evaluation.