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Related Experiment Video

Updated: Mar 3, 2026

Designing CAD/CAM Surgical Guides for Maxillary Reconstruction Using an In-house Approach
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A validation study of reconstructed rapid prototyping models produced by two technologies.

Christian Andreas Dietrich, Andreas Ender, Stefan Baumgartner

    The Angle Orthodontist
    |May 2, 2017
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    Summary

    This study compared stereolithography (SLA) and PolyJet rapid prototyping for 3D orthodontic models. PolyJet offered better trueness, while SLA provided superior precision, with both suitable for diagnostics and treatment planning.

    Keywords:
    3D printingDental castsRapid prototypingStereolithography

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    Area of Science:

    • Orthodontics
    • Biomedical Engineering
    • Digital Dentistry

    Background:

    • Accurate 3D digital orthodontic study casts are crucial for diagnostics and treatment planning.
    • Rapid prototyping (RP) offers a method for physical reproduction of these digital models.
    • Evaluating the accuracy of different RP techniques is essential for clinical application.

    Purpose of the Study:

    • To compare the accuracy (trueness and precision) of stereolithography (SLA) and PolyJet rapid prototyping systems.
    • To assess the physical reproduction fidelity of three-dimensional (3D) digital orthodontic study casts using two different RP techniques.
    • To determine the suitability of these RP techniques for clinical orthodontic applications.

    Main Methods:

    • Two 3D STL files of maxillary dentitions were used as references.
    • Five rapid prototyping replicas were fabricated per case using both SLA and PolyJet systems.
    • Surface superimpositions and statistical analyses (independent-sample t-tests) were performed to evaluate trueness and precision.

    Main Results:

    • Both SLA and PolyJet systems demonstrated statistically significant differences in trueness and precision.
    • Precision was high for both systems, with mean deviations of 23 (±6) μm for SLA and 46 (±13) μm for PolyJet.
    • PolyJet replicas showed higher trueness (mean deviation 66 ±14 μm) compared to SLA models (109 ±4 μm).

    Conclusions:

    • PolyJet rapid prototyping exhibited superior trueness in reproducing digital orthodontic models compared to SLA.
    • Stereolithography (SLA) demonstrated higher precision in the physical reproduction of these models.
    • Despite observed dimensional errors (max 127 μm), both SLA and PolyJet techniques are deemed suitable for orthodontic diagnostics and treatment planning.