Dimensional accuracy and surface characteristics of 3D-printed dental casts.

Statement Of Problem: Although studies have reported the accuracy of 3D-printed dental casts, studies addressing cast distortion throughout the complete-arch range are lacking.

Purpose: The purpose of this in vitro study was to evaluate the dimensional accuracy of different areas in complete-arch casts made with various 3D printing methods.

Material And Methods: A computer-aided design (CAD) reference cast was modified from a mandibular cast by adding 6 cylinders in the canine, second premolar, and second molar locations and 3 spheres to define a coordinate system. A total of 50 casts were printed with 5 group materials, which included fused deposition modeling (FDM), digital light processing (DLP1 and DLP2), photopolymer jetting (Polyjet), and stereolithography (SLA). After scanning the 3D printed casts, the overall consistency was examined by superimposing them on the CAD reference cast and measuring the deviations. For dimensional accuracy, cylinder top coordinates were extracted from each printed cast, and X-, Y-, and Z-deviations and the 3D deviation were calculated by subtracting the coordinates of the CAD reference cast from the cast values. Statistical analyses were conducted by the Kruskal-Wallis test and the Mann-Whitney post hoc test (α=.05). Surface characteristics were examined with photographs and scanning electron micrographs.

Results: FDM showed more systemic deviations than DLP, Polyjet, and SLA from superimposing analysis (P<.01). In the X-axis, FDM and DLP showed contraction, while Polyjet and SLA showed expansion (P<.01). In the Y-axis, FDM showed forward deviations on the right side and DLP showed contraction (P<.01). Three-dimensional deviation at each cylinder location was lowest in the left canine region, and deviations increased with distance from this site in all groups. The qualitative features of casts varied among 3D printers in terms of shape, surface smoothness, and edge sharpness.

Conclusions: FDM and DLP casts tended to contract, whereas casts in the Polyjet and SLA groups expanded buccolingually and anterioposteriorly. Vertically, deviations were smaller than those in the other directions.