Evaluation of the accuracy (trueness and precision) of a maxillary trial denture according to the layer thickness: An in vitro study

Abstract Statement of problem Layer thickness in additive manufacturing has stair-step effects that greatly affect the accuracy of the definitive prosthesis. Although the layer thickness can be set, insufficient data comparing and analyzing the accuracy of the fabricated prosthesis after adjusting the layer thickness are available. Purpose The purpose of this in vitro study was to evaluate and compare the accuracy of trial dentures fabricated with different layer thicknesses by using stereolithography (SLA) apparatus. Material and methods A maxillary complete edentulous cast was duplicated with silicone material to make a master gypsum cast which was scanned by using a laboratory scanner and saved as a standard tessellation language (STL) file. This was exported into a computer-aided design software program to produce and store the trial denture. Twenty dentures were fabricated according to the set layer thicknesses (50 μm and 100 μm) by using the SLA. The trueness was measured by scanning the intaglio and cameo surfaces to find the best overlap with the reference model to obtain the root mean square value. The precision was evaluated based on the RMS value gained by superimposing the identical scan data from each group and using the combination formula. The Mann-Whitney U-test was used to confirm significant differences among the groups (α=.05). Results The trueness of the 50-μm-SLA trial denture and the 100-μm-SLA trial denture was significantly different for the intaglio and cameo surfaces (P Conclusions It is clinically more appropriate to set the layer thickness to 100 μm rather than 50 μm for the fabrication of accurate trial dentures by using SLA.