Aim: This study aimed to compare the surface roughness of 3D-printed denture base and teeth polymers with conventional heat-polymerized acrylic resin to evaluate their clinical suitability.

Materials and methods: Sixty cylindrical specimens (18 mm × 3 mm) were fabricated and divided into three groups: Group A – 3D-printed Denture Base Resin; Group B – 3D-printed Denture Teeth Resin; and Group C – heat-polymerized Superacryl Plus (control). Specimens were processed following standardized protocols for polishing and post-polymerization. Surface topography and roughness parameters (Ra, Rq, Rmax) were measured using atomic force microscopy (AFM). Data were analyzed using descriptive statistics, and intergroup differences were assessed with the non-parametric Mann–Whitney test (p < 0.01).

Results: Both 3D-printed resins exhibited higher surface roughness than the heat-polymerized control, with Group B showing the highest Ra and Rq values, followed by Group A. Rmax values followed a similar pattern (Group B: 328.84 nm; Group A: 286.83 nm; Group C: 77.93 nm). No significant differences were found between the two 3D-printed resins. Despite variations, all materials remained within clinically acceptable roughness limits, although none reached the threshold Ra of 0.2 µm.

Conclusion: The present study demonstrated that conventional heat-polymerized acrylic resin exhibits significantly lower surface roughness compared to 3D-printed denture base and teeth resins. Among the 3D-printed materials, the one used for the teeth showed the highest roughness values, followed by the material for denture bases. These findings highlight the influence of manufacturing technique and material type on surface properties, which may impact microbial colonization and denture hygiene.