Comparison of accuracy in digital and conventional cross-mounting

The use of digital interocclusal registration scans for virtual articulation and mounting has been studied extensively; however, the accuracy of the cross-mounting procedures in a digital workflow is not well understood.

The purpose of this in vitro study was to compare the accuracy of digital and conventional cross-mounting by measuring the 3-dimensional deviation at each step of sequential cross-mounting.

A set of reference casts and complete arch interim restorations was prepared for complete arch complete-coverage restorations, hand-articulated, and mounted in an articulator. The reference casts were then scanned with and without the interim restorations to generate 4 reference casts for cross-mounting. For the conventional group, 15 sets of the 4 casts were printed. Polyvinyl siloxane interocclusal registration records were made of the reference casts for each set, and casts were sequentially cross-mounted. For the digital workflow, 15 sets of bilateral interocclusal registration scans were made of the mounted reference casts and used to align the cast scans. Three-dimensional deviations at 2 anterior and 2 posterior points were recorded between the experimental mountings and the reference casts on each set of casts. Nonpaired t test and analysis of variance (ANOVA) were used to compare the average discrepancy between the 2 groups, and the pooled anterior versus posterior discrepancies were compared (α=.05).

A significant difference was found between conventional and digital cross-mounting procedures (P<.001), but no significant difference was found in either group, conventional (P=.116) or digital (P=.987), at each step of the sequential mountings. The mean ±standard deviation at the final set of related casts in the conventional workflow was 201.6 ±137.0 μm and that in the digital group was 50.3 ±47.5 μm, with a significant difference between anterior and posterior deviations in the digital group (P=.028), but not in the conventional group (P=.143). The mean ±standard deviation anterior conventional deviation was 175.6 ±119.2 μm and that in the digital group was 36.9 ±30.9 μm. The mean ±standard deviation posterior conventional deviation was 227.6 ±50.2 μm and that in the digital group was 63.7 ±57.2 μm.

Digital cross-mounting was more accurate than conventional cross-mounting, although increased deviation was found in the anterior region compared with the posterior region.