Influence of additive manufacturing method and build angle on the accuracy of 3D-printed palatal plates

In this in vitro study, the effects of additive manufacturing (AM) methods and build angles on the trueness and precision of 3D-printed palatal plate orthodontic appliances for newborns and infants were examined. Specimens were fabricated by different representative AM methods, including digital light processing (DLP), fused filament fabrication (FFF), and MultiJet printing (MJP). Three build angles (0°, 45°, and 90°) were used. After scanning, all specimens were analyzed using the 3D inspection software. The root mean square values were measured for trueness and precision. Color maps were created to detect deviations in samples. The data were statistically analyzed with a two-way ANOVA. The trueness and precision were statistically influenced by both AM methods and build angles (p < 0.05). Moreover, the root mean square values of the 45° DLP (0.0221 ± 0.0017 μm) and the 0° MJP (0.0217 ± 0.0014 μm) were significantly lower compared to those in other groups (p < 0.001). AM methods (DLP, FFF, and MJP) and build angles (0°, 45°, and 90°) significantly impacted the dimensional accuracy of additively manufactured palatal plate orthodontic appliances. Also, the 45° DLP and the 0° MJP were associated with the highest trueness and precision. All tested AM methods with different build angles yielded clinically acceptable outcomes (within an acceptance range of ±300 μm for trueness), achieving the highest accuracy with a technology-specific suitable build angle.