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

Abstract 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.