Accuracy of 3D-Scanned Full-Arch Dentition Versus 3D-Printed Models Generated Using Various 3D Printers Based on Linear Measurements

AIM AND OBJECTIVES: To evaluate the accuracy of 3D-scanned full-arch dentition and 3D-printed models generated from various 3D printers and resin combinations using linear measurements. MATERIALS AND METHODS: Intraoral scans of the mandibular arches of 30 patients were obtained using Primescan Dentsply Sirona (Dentsply Sirona Inc., USA/Germany), exported as Standard Tessellation Language (STL) files, and mesiodistal, intercanine, and intermolar width measurements were made using Maestro 3D Dental Studio software, version 6.0 (AGE Solutions S.r.l., Italy), as the reference standard. STL files were processed using Chitubox Basic software, version 2.3 (CBD-Tech (Shenzhen) Co., Ltd., China), and printed using stereolithography (SLA) 3D printers: Phrozen Sonic Mighty 4K (Phrozen Technology Co., Ltd., Taiwan) and Elegoo Saturn Ultra 4K (Shenzhen Elegoo Technology Co., Ltd., China), with Phrozen Aqua Gray 4K and Elegoo Standard photopolymer resins, yielding 120 models (30/group). Models were cleaned and cured using an Anycubic Cleaning and Curing Machine-Plus (Shenzhen Anycubic Technology Co., Ltd., China) and measured with Vernier calipers (Mitutoyo Corporation, Japan). Intra-examiner reliability was assessed after one week. RESULTS: Data were analyzed using one-way analysis of variance (ANOVA) and a post hoc Tukey test. The intraclass correlation coefficient (ICC) confirmed intra-examiner reliability (ICC > 0.98). No significant differences (p > 0.05) were observed between printed models and intraoral scans. The Elegoo printer with Phrozen resin showed the highest accuracy, while the Phrozen printer with Elegoo resin showed some deviation; all measurements were within clinically acceptable limits. CONCLUSION: 3D-printed models showed comparable linear measurement accuracy to intraoral scans, with consistent reliability and clinically acceptable variations across printer-resin combinations.