The effect of two different layer heights on the accuracy of 3-D Printed Orthodontic Models

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Abstract Background: Additive manufacturing is widely used in the dental field. The accuracy of the printed object produced by additive manufacturer is considered questionable based on the printer’s type, resolution, and the layer height. This study aimed to assess the accuracy of the 3D printed model by DLP technology at 50-µm and 100-µm layer height Methodology: A desktop scanner, R700 desktop scanner (3Shape, Copenhagen, Denmark) was used to scan an orthodontic typo-dent cast to acquire digital scans. A total number of (20) models were printed using a Digital Light Processing 3D printer and divided into two separate group. The 1st group (n=10) and the 2nd (n=10) groups were printed at 50-μm and 100-μm layer heights respectively. All printed models were digitally scanned. Assessment was performed using the GOM Inspect suite to register both the reference and 3D printed digital models to detect the deviation in both X, Y, and Z axes. Results: In the molar area, 50-µm layer thickness showed statistically significant difference in the right side when compared with 100-µm while the left side showed no difference. In the premolar region, there was no statistically significant differences between both groups in the right side except for the z-axis. The canine area demonstrated that the 50-µm layer height was statistically significant lower in deviation than 100-µm group in all directions. There was a strong agreement between both observers that was statistically significant (ICC=0.965, 95%CI= (0.958:0.971), p<0.001). Conclusion: Within the limitations of the study and the type and the parameters of the DLP printer used, the results of our research as a whole show that models printed at 50-μm display lower deviations in X, Y, and Z axes with a more consistent distortion pattern when compared to 100-μm models. Besides, the ideal thickness for high precision requirements is 50 µm, whereas, 100-μm could be used in printing diagnostic models.

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