Comparison of dental arch measurements between 3D-printed, digital, and stone casts.

BACKGROUND: The use of computer-aided design and manufacturing technologies in diagnosis, treatment planning, and fabrication of prosthetic restoration is changing how prosthodontic treatment is offered to patients. This study compares the precision of three-dimensional (3D) printed casts produced from optical scanners using the stereolithographic 3D printing technique, their digital replicas, and conventional stone casts. MATERIALS AND METHODS: Impressions were taken from 13 patients. Inter-arch widths (intercanine/premolar/molar) were made for digital and prototyped models and compared with the original stone casts. The measurements on printed and conventional casts were taken using a digital caliper, whereas those on digital casts were measured directly. RESULTS: Digital casts showed significantly higher maxillary and mandibular intercanine width measurements than 3D-printed and Stone (Gypsum) measurements counterparts (p < 0.001). Additionally, digital casts exhibited significantly lower maxillary and mandibular inter-1st molar and inter-2nd molar widths than their 3D printed and gypsum counterparts (p < 0.001). There were no statistically significant differences between measurements obtained with gypsum and 3D-printed casts. CONCLUSION: The 3D-printed casts may be considered a viable alternative to gypsum casts, offering clinically acceptable precision for diagnosis, treatment planning, and the fabrication of prosthetic restorations. On the other hand, digital cast measurements exhibit significant variations from gypsum and 3D-printed casts.