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Evaluation of the Dimensional Accuracy of 3D-Printed Aligners: An In Vitro Study Using Reverse Engineering Analysis.

Samuele Avolese1,2, Fabrizio Sanna1,2, Simone Parrini2

  • 1Department of Mechanical and Aerospace Engineering, Polytechnic University of Turin, 10129 Torino, Italy.

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Summary
This summary is machine-generated.

Manual removal of print supports before final curing significantly impacts the dimensional accuracy of 3D-printed aligners. This post-processing step alters internal geometry, affecting overall dimensional stability.

Keywords:
3-dimensional printing3D scannerdigital modelsdigital simulationpost-processing

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Area of Science:

  • Biomaterials Engineering
  • Dental Technology
  • Additive Manufacturing

Background:

  • Investigating dimensional deformation in 3D-printed aligners fabricated with TC-85 DAC resin.
  • Assessing the impact of manual support removal before final curing on aligner dimensional accuracy.

Purpose of the Study:

  • To evaluate the effect of post-processing techniques on the dimensional accuracy of 3D-printed dental aligners.
  • To determine if support removal influences the final geometry of 3D-printed aligners.

Main Methods:

  • Digital design of aligners using uDesign Direct Aligner software.
  • 3D printing of aligners using TC-85 DAC resin, with and without support removal before final curing.
  • Digitization and comparison of printed aligners to digital designs using RMS and inter-second molar distance.

Main Results:

  • Statistically significant differences (p < 0.0001) were observed between aligners produced with and without support removal.
  • Manual support removal before final curing led to significant dimensional variations.

Conclusions:

  • Manual removal of print supports before final curing negatively affects the dimensional accuracy of 3D-printed aligners.
  • Post-processing conditions, specifically support removal, significantly alter the internal geometry and dimensional stability of 3D-printed aligners.