Evaluating the accuracy of one-piece and three-piece 3D-printed indirect bonding transfer trays: An in vitro study

Recent developments in computer-aided design/computer-aided manufacturing (CAD/CAM) and 3D printing have enabled the fabrication of digital indirect bonding (IDB) transfer trays. These modern products require thorough investigation.

The aim of the study was to determine the accuracy of one-piece and three-piece IDB transfer trays in vitro.

An initial dental scan (IDS) of a randomly selected patient with digitally positioned brackets served as the master scan (MS) for designing 16 IDB transfer trays of each type. They were 3D printed and used for bonding 448 brackets to the models. Subsequently, the models were scanned with a TRIOS® 3 Intraoral Scanner (3Shape A/S, Copenhagen, Denmark), producing actual scans (ASs). The accuracy of bracket positioning was measured digitally on both MSs and ASs. The measurements were compared to the Objective Grading System for dental casts provided by the American Board of Orthodontics (ABO).

The 2 types of IDB transfer trays showed comparable accuracy. All linear errors were within the clinically acceptable range, whereas the angular measurements demonstrated significant variability, resulting in clinically unacceptable transfer errors that ranged from 3.3% to 90.3%.

The study results cannot be unconditionally extrapolated to other types of IDB transfer trays due to the diversity of their properties and features. The study evaluated the in vitro accuracy of IDB transfer trays. The revealed number of errors may be even higher in vivo due to limitations in visibility, salivary flow, interference from the tongue, and difficulties in achieving a proper fit of the IDB transfer tray to the teeth.