Introduction: Digital setups are reliable and show numerous benefits to the orthodontic practice. Fused deposition modeling can build physical replicas of these setup models. The purpose of this study was to compare 3-dimensional printed and conventional setups. Methods: Ten sets of pretreatment plaster models were randomly selected and scanned to obtain digital replicas. Conventional and virtual setups were constructed based on the treatment plan, anchorage needs, and extraction pattern. The same arch form was used for corresponding conventional and digital setups by replicating the archwire on the screen with the use of the 1:1 real scaling tool in the Orthoanalyzer software (3Shape, Copenhagen, Denmark). Printed and manual setups were measured to compare dimensional accuracy and inter-and intra-arch characteristics. The differences were assessed by means of paired t test analyses. Results: The majority of measurements showed higher values on the manual setup models. Statistically significant differences were found in 6 dimensional-accuracy measurements (from À0.04 to 0.32 mm). One intra-arch (from 0.01 to 1.55 mm) and all inter-arch (from 0.87 to 0.95 mm) characteristics showed statistically significant differences. Maxillary models exhibited greater variations than mandibular setup models. Conclusions: Three-dimensional setups printed with fused deposition modeling are not comparable to conventional setups. The digital setup process should be managed with care to avoid tooth collision and overcome software limitations. (Am J Orthod Dentofacial Orthop 2019;155:288-95) D igital impressions and scanning systems were introduced into the dental practice in 1980. 1 Three-dimensional (3D) imaging and modeling technology has undergone significant advances, allowing more precise models, complete analyses, and editing tools such as virtual setup models, occlusal maps, and model segmentation on demand. Virtual models also have many actual or at least potential benefits against plaster models, such as reducing physical storage demand, lowering risk of loss or damage, facilitating classification, improving communication, and data sharing. 2-9 Numerous studies have proven that measurements made on 3D digital study models of dental casts have the same accuracy and precision as those those made directly on traditional plaster models. 3,10-13 Digital and manual setup models have been shown to be reliable when measured. 14,15 These results imply that virtual setup models can be used for treatment planning, better understanding of treatment limitations, anchorage needs, and predictive assessment of treatment results. 16 Virtual setups can also be merged with cone-beam computerized tomographic scans to include roots, providing a complete view of tooth position. 4,17-20 However, physical models and setup models are still being used for some laboratory procedures, such as indirect bonding, customized appliance, clear aligners, and surgical wafer fabrication. 21-28 3D model reconstruction can be made by several techniques, called a...