Dimensional Accuracy of 3D-Printed, Digital and Conventional Stone Dental Cast of Dentate Patients Using Arch and Teeth Measurements

Aim: This study aimed to compare the conventional, digital, and three-dimensional (3D)-printed casts in terms of their accuracy in quantifying arch and teeth measurements. Materials and Methods: The conventional casts were prepared using polyether dental impressions. Digital impressions of the typodont reference casts were accomplished using an intra-oral scanner. The digital casts were first converted to stereolithography (STL) files which were then edited, and printed using an SLA printer and photo-polymer resin material. The measurements of the first two groups were completed using a digital caliper, while an imaging software was used to measure digital casts. The occlusocervial (OC) height and mesiodistal (MD) width of canines, second premolars (PMs), and molars of each jaw were measured. Additionally, intercanine width (ICW) and intermolar width (IMW) were also measured. Results: Overall, the lowest OC measurement errors were observed for 3D-printed casts for the upper canine, lower canine, and lower molar (0.003 +/- 0.01 mm). Similarly, the lowest MD measurement errors were observed for 3D-printed casts for upper canine, upper PM, and lower PM (0.002 +/- 0.01 mm). The ICW and IMW measurement errors for the 3D-printed casts were significantly lower (p < 0.01) for the upper ICW (0.011 +/- 0.01 mm) and lower IMW (0.017 +/- 0.01 mm) than the other two groups. Compared to the conventional and digital casts, the lower ICW (0.013 +/- 0.01 mm) and upper IMW (0.017 +/- 0.01 mm) measurement errors observed for the 3D-printed casts were also lower, but non-significantly (p > 0. 01). Conclusions: 3D-printed casts presented the lowest OC, MD, ICW, and IMW measurement errors, than the conventional and digital casts. The highest measurement errors were associated with the digital casts.