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Multi-objective optimization for enhanced digitalization in direct 3D printing: an application in dentistry.

Anmol Sharma1, Pushpendra S Bharti2, Ashish Kaushik3

  • 1USICT, Guru Gobind Singh Indraprastha University, Sector 16C, Dwarka, Delhi, 110078, India. Anmol.20916490021@ipu.ac.in.

Clinical Oral Investigations
|April 11, 2025
PubMed
Summary

Optimizing 3D scanning parameters for dental appliances significantly improves accuracy and efficiency. This study found optimal settings for scan distance, angle, and light intensity to minimize deviation and file size for better 3D printing outcomes.

Keywords:
3D printing3D scanningDentistryNSGA IIStl files

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Area of Science:

  • Digital dentistry
  • Additive manufacturing
  • Surface reconstruction

Background:

  • Scanned STL (stereolithography) files are crucial for direct 3D printing of dental appliances.
  • Variances between scanned files and original models impact accuracy and require preprocessing.
  • Optimizing STL mesh quality is essential for balancing resolution, memory, and accuracy.

Purpose of the Study:

  • To mitigate variances in scanned STL files for accurate dental appliance manufacturing.
  • To optimize STL mesh triangles for improved digital model quality and reduced memory usage.
  • To identify optimal scanning parameters (scan distance, angle, light intensity) for enhanced 3D printing efficiency and accuracy.

Main Methods:

  • Response surface methodology was used to design experiments with varying scan distance (SD), scan angle (SA), and light intensity (LI).
  • 20 experimental runs were conducted using a denture, evaluating output deviation, triangle count, and time.
  • A predictive model for deviation was developed and optimized using a multi-objective Non-dominated Sorting Genetic Algorithm II.

Main Results:

  • Regression and Artificial Neural Network (ANN) models demonstrated significant predictive capabilities for deviation.
  • Optimal parameters identified: SD of 5.3621 inches, SA of 82.1746 degrees, and LI of 15.2456 W/m².
  • Optimized parameters resulted in an average deviation (AD) of 0.1964, 27,811 triangles (NT), and 89.2203 seconds of consumed time.

Conclusions:

  • STL file accuracy is dependent on mesh quality; preprocessing is often needed.
  • Balancing mesh triangle count for resolution and memory usage is critical.
  • Optimized scanning parameters enhance dental appliance accuracy, efficiency, and patient outcomes in digital dentistry.