3D-printed zirconia orthodontic brackets: Effect of printing method on dimensional accuracy.

Objectives: This study investigated the effect of additive manufacturing (AM) methods on the slot height dimensions and accuracy of 3D-printed orthodontic brackets.

Methods: A 3D model of a standard Mclaughlin Bennett Trevisi bracket was used as a reference to print the ceramic bracket in a 90° orientation using two representative AM methods: digital light processing (DLP) and material jetting (MJ). The dimensional accuracy and slot heights were determined using a scanning electron microscope and an optical scanner. Also, all specimens were analysed using the Geomagic Control X 3D inspection software. The root mean square (RMS) values were used for trueness and precision assessment. Statistical analyses were performed using an independent sample t-test.

Results: Slot height dimensions, trueness RMS, and precision RMS were statistically affected by different AM methods (p < .01). There was a significant difference between the different printing methods, with DLP meeting the tolerance requirements (mean slot height = 0.557 ± 0.018 mm) and MJ being slightly below them (mean slot height = 0.544 ± 0.021 mm). However, MJ significantly outperformed DLP in terms of accuracy. Among the two printing methods, MJ was associated with higher trueness (RMS = 0.025 ± 0.004 mm) and precision (RMS = 0.038 ± 0.005 mm).

Conclusions: Both tested AM methods yielded clinically acceptable outcomes, with the RMS range set to ±100 μm and the slot height tolerance established at 0.549-0.569 mm. The MJ technology achieved the highest accuracy.