Stereolithography vs. Direct Light Processing for Rapid Manufacturing of Complete Denture Bases: An In Vitro Accuracy Analysis

Abstract

The topical literature lacks any comparison between stereolithography (SLA) and direct light processing (DLP) printing methods with regard to the accuracy of complete denture base fabrication, thereby utilizing materials certified for this purpose. In order to investigate this aspect, 15 denture bases were printed with SLA and DLP methods using three build angles: 0°, 45° and 90°. The dentures were digitalized using a laboratory scanner (D2000, 3Shape) and analyzed in analyzing software (Geomagic Control X, 3D systems). Differences between 3D datasets were measured using the root mean square (RMS) value for trueness and precision and mean and maximum deviations were obtained for each denture base. The data were statistically analyzed using two-way ANOVA and Tukey’s multiple comparison test. A heat map was generated to display the locations of the deviations within the intaglio surface. The overall tendency indicated that SLA denture bases had significantly higher trueness for most build angles compared to DLP (p < 0.001). The 90° build angle may provide the best trueness for both SLA and DLP. With regard to precision, statistically significant differences were found in the build angles only. Higher precision was revealed in the DLP angle of 0° in comparison to the 45° and 90° angles.

Accuracy Evaluation of Additively and Subtractively Fabricated Palatal Plate Orthodontic Appliances for Newborns and Infants – An In-vitro Study

“…DLP showed a significantly improved trueness and precision at 100 µm in comparison to SLA. Values found in literature for both SLA and DLP employed in denture and bite splints, comprised of higher RMS values than the ones observed in this study [2,3,17,23,24,32], hence lower accuracy. Some studies agreed with the superiority of accuracy of DLP in comparison to SLA found in this study [33], while other ones exhibit greater accuracy for SLA [32].…”

“…Nonetheless due to the different scale and sizing of the appliances, as well as the different material used, the results from palatal plate accuracy might vary. Although there are accuracy research studies in splint materials [2], as well as for dentures [32], potential material combinations and technologies (conventional, AM, SM) have not yet been tested under uniform testing conditions for the given application.…”

“…The palatal plates are smaller than other AM dentistry applications such as dentures and bite splints. Dimensionally larger and/or larger curved surfaces are more prone to the staircase effect than vertical surfaces, which leads to higher dimensional errors [32]. It might also be that when printing smaller samples, less mechanical forces need to be exerted for lifting the printing platform, which might have led to smaller surface deviations and deformations.…”

3D Printing in Digital Prosthetic Dentistry: An Overview of Recent Developments in Additive Manufacturing

“…RPD’s made of CoCr using additive technologies have already found their way into dental laboratories and practices. Currently, more and more publications on additive manufacturing of complete dentures are being published [ 79 , 80 , 81 , 82 ]. The results regarding mechanical strength, fit, and surface quality are promising.…”

3D printing in dentistry – Exploring the new horizons

“…The most common types of 3D printing technology in dentistry are stereolithography (SLA), digital light processing (DLP), and material jetting (MJ). 8 , 9 These machines use additive manufacturing techniques to generate a product on top of the printer's build platform. The capabilities to produce various material types such as ceramic, metal, or thermoplastic resin.…”