EFFICACY OF A NOVEL 3D-PRINTED ANTI-TEETH BREAKER FOR DENTAL PROTECTION DURING RIGID LARYNGOSCOPY AND ENDOTRACHEAL INTUBATION: A PROSPECTIVE RANDOMISED COMPARATIVE STUDY

Abstract

Background: Dental injury is among the most prevalent peri-anaesthetic complications, carrying significant medico-legal implications. Conventional protective strategies lack standardisation and stability. We evaluated a novel 3D-printed anti teeth breaker device against conventional dental padding during rigid laryngoscopy. Methods: In this prospective randomised controlled study conducted at Saveetha Medical College and Hospital (June December 2025), 60 adult patients (ASA I–II) undergoing elective surgery under general anaesthesia requiring endotracheal intubation were randomised to receive either a 3D-printed anti-teeth breaker (Group A, n = 30) or conventional dental padding (Group B, n = 30). Primary outcome was incidence of dental injury. Secondary outcomes included pressure marks, intubation time, ease of laryngoscopy and intubation (3-point Likert scale), haemodynamic responses, and operator satisfaction. Results: Baseline demographics were comparable between groups. No dental injury occurred in Group A, compared with 7 cases (23.3%) in Group B (p = 0.01, Fisher's exact). Pressure marks were significantly reduced in Group A (3.3% vs 40.0%; p < 0.001). Intubation time was significantly shorter in Group A (15.1 ± 2.6 s vs 22.0 ± 3.8 s; p < 0.001). Ease of laryngoscopy, ease of intubation, and operator satisfaction were all significantly superior in Group A (p < 0.001 each). Conclusion: The 3D-printed anti-teeth breaker eliminated dental injury, reduced pressure-related complications, shortened intubation time, and improved operator satisfaction compared with conventional dental padding. This low-cost innovation holds significant potential for integration into routine anaesthesia practice and airway safety guidelines.