Comparison of intraoral scanning and CBCT to generate digital and 3D-printed casts by fused deposition modeling and digital light processing

Objectives: to evaluate trueness and precision of digital casts from intraoral scanning (IOS) and cone beam computed tomography (CBCT); trueness and precision of 3D-printed casts using digital light processing (DLP) and fused deposition modeling (FDM); the influence of digitizing method in the 3D-printed casts and, to compare STL data after DICOM segmentation and conversion.Methods: a reference cast was digitized with IOS and CBCT, and 3D-printed using FDM and DLP. Linear mea-surements of occlusocervical (OC), interarch (IEA), and mesiodistal (MD) dimensions were taken on reference, digital and 3D-printed casts. Trueness was observed as the distortion, and precision was observed as the variation of measurements. One and Two-way ANOVA, Student t-test, and Chi-Square were applied to analyze data.Results: distortion varied between digital casts for all dimensions; at OC, both showed expanded dimensions with IOS being significantly greater; in turn, CBCT digital casts showed higher distortion at IEA and MD. Dimensions of 3D-printed casts showed a predominance of shrinkage, DLP presented higher distortion compared to FDM for both digitizing methods. Digitizing methods influenced the 3D-printing of casts, especially for DLP. Regarding precision, no statistical difference was found. STL converted from DICOM showed statistical difference in IEA (p < 0.001).Conclusions: digital casts showed distortion depending on the digitizing method. IOS was better in IEA and MD, and CBCT in OC dimensions. Overall, DLP casts presented higher distortion compared to FDM. The digitizing method influences trueness on 3D-printed casts. File conversion from DICOM to STL per se could change the dimension. Clinical Significance: This investigation showed that digital casts from IOS and CBCT as well 3D-printed casts from FDM and DLP can show different trueness. It is clinically relevant as clinicians have various workflows available in Digital Dentistry which involve these digitizing and manufacturing methods.