Effect of Different Printing Designs and Resin Types on the Accuracy of Orthodontic Model

This study aimed to evaluate the effect of resin type and printing design on the dimensional accuracy of three dimensional (3D) printed orthodontic models, considering their clinical relevance for applications such as in-house aligner fabrication. Since low-cost Liquid Crystal Display (LCD) printers have been increasingly adopted in practice but data on their trueness and precision with different resins and print designs were limited, the study sought to provide evidence-based insights into their reliability. A mandibular model was designed using Blenderfordental (B4D, version 1.1.2024; Dubai, United Arab Emirates) software and fabricated with the Anycubic Photon Mono 7 Pro 14K (Anycubic, Shenzhen, China) LCD printer. The model was printed in vertical orientation using three different print designs at two layer thicknesses (50 µm and 100 µm). Four resins (Elegoo, Anycubic, eSUN, and Phrozen) were used, and each resin was printed with all three designs, yielding 126 models per resin and a total of 504 printed models. Dimensional deviations between the printed and reference models were assessed using root mean square (RMS) values and color-coded deviation maps. Significant differences in trueness were found among resins and print designs at both layer thicknesses (p < 0.001). At a layer thickness of 50 µm, eSUN and Anycubic showed superior trueness, whereas Phrozen exhibited the highest deviations. At a layer thickness of 100 µm, Anycubic, eSUN, and Phrozen generally performed better than Elegoo. Overall, printing at 100 µm yielded better performance than at 50 µm. Precision analysis revealed resin-dependent differences, with eSUN showing significantly higher precision than Elegoo at both layer thicknesses (p = 0.006 at 100 µm, p < 0.001 at 50 µm) and superior precision compared to Phrozen at 50 µm (p = 0.019). Both resin selection and print design significantly affect the dimensional accuracy of 3D-printed dental models.