Odour Perception of In-Office Orthodontic 3D Printing and Its Health Implications

Abstract

Introduction: In-office clear aligner fabrication involves the usage of an organic chemical called a polymer resin, for 3D printing, which exposes the orthodontic personnel to possible harmful effects of handling and inhalation of vapours of uncured resin. While mechanical accuracy and efficiency are well documented, sensory and occupational aspects such as odour perception and associated symptoms remain underreported.

Objectives: To evaluate odour perception and associated transient sensory symptoms during in-office orthodontic 3D printing performed under standardized clinical conditions.

Methods: Two commercially available 3D printing resins (SprintRay^® Die and Model 2 resin and Taglus^® Model resin) were used to print 40 Orthodontic models each with 4 models per day across a 10-day printing schedule. Orthodontic models were printed within a dedicated laboratory environment utilizing a synchronized SprintRay^® 3D printing ecosystem. Fifteen assessors perceived odour immediately after printing and at 24 hours using a five-point Likert scale. Transient symptoms including eye irritation and headache were also recorded.

Results: Mean immediate odour scores were higher for SprintRay^® Die and Model 2 resin (3.05 ± 0.45) compared with Taglus^® Model resin (2.15 ± 0.40). At 24 hours, odour perception decreased for both materials but remained higher for SprintRay^® Die and Model 2 resin (2.15 ± 0.40 vs 1.30 ± 0.35). Mild transient symptoms were also similarly reported by the participants.

Conclusion: In-office orthodontic 3D printing demonstrated material-dependent differences in odour perception and mild sensory symptoms. SprintRay^® Die and Model 2 resin exhibited higher immediate odour scores compared with Taglus^® Model resin, with residual differences persisting at 24 hours. Environmental ventilation and material selection may influence occupational comfort and mitigate health risks in an in-office clear aligner setup.