Effect of print angle on dimensional accuracy and printing efficiency of directly 3D-printed clear aligners

초록

This study evaluated the effect of print angulation on the dimensional accuracy and production efficiency of directly 3D-printed clear aligners fabricated with a high-resolution LCD printer and a clinically available, FDA-cleared clear resin (Clear Miracle Resin; ODS Co., Ltd., Inchon, Korea). Seventy aligners were produced in seven orientations (0 degrees, A30 degrees, A60 degrees, A90 degrees, P30 degrees, P60 degrees, P90 degrees) with a 50-mu m layer height. Dimensional accuracy was assessed using root mean square (RMS) deviation, linear and angular measurements, and height analysis complemented by color-coded deviation maps. Printing time was also recorded. Statistical comparisons were performed using the Kruskal-Wallis test with post-hoc analysis at a significance level of 0.05. Print angulation significantly influenced RMS as well as linear, angular, and height deviations. The 0 degrees orientation achieved the lowest RMS and the shortest print time, while A90 degrees and P90 degrees showed higher deviations and greater vertical reduction. All groups exhibited negative height deviations, with the 0 degrees, P30 degrees, and P60 degrees orientations demonstrating minimal deviations. These findings indicate that print angulation measurably affects both accuracy and efficiency of direct aligner printing. The 0 degrees orientation provided the most accurate fit, fastest production, and good predictability, underscoring the importance of angulation selection.

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