Evaluating 3D Printed Dental Models of Varying Wall Thicknesses for Maximizing Cost-Effectiveness & Time Efficiency

Abstract

Introduction:

The field of dentistry & Orthodontics as well has increasingly adopted 3D printing technology. In Orthodontics it is used to expedite the production of custom made aligners, which provide aesthetic benefits and comfortable patient experience. Traditional methods of sourcing aligners from dental labs/companies is decline as it is costly and time consuming, prompting a shift towards in-office 3D printing for manufacturing of clear aligners.

Aim and Objective:

The primary aim of the article is to assess the cost-effectiveness by analyzing resin usage across a range of wall thicknesses and solid models in 3D printing. The secondary aim is to compare the printing time and resin material consumption of horizontal and vertical orientations for varying wall thicknesses and solid models.

Materials and Methods:

The study employed a compatible 3D printer in conjunction with standard photopolymer resin material. The models were hollowed and printing parameters were configured using Meshmixer & Chitubox Dental software respectively. A total of 400 models were produced, with 40 models for each specified wall thickness (1mm, 1.25mm, 1.5mm, 1.75mm, 2mm, 2.25mm, 2.5mm, 2.75mm, 3mm, and solid). Resin consumption (in milliliters) was measured for individual models as well as for monthly production. The study included a comparative analysis of horizontal versus vertical printing orientations. Additionally, a percentage analysis of resin efficiency and the number of models printable per bottle of resin were performed.

Results:

Findings of our study demonstrate a direct relationship between model wall thickness and resin usage. The resin savings achieved with varying model wall thicknesses compared to a solid model, emphasizing significant material efficiency. Specifically, transitioning from a solid model to one with a wall thickness of 1.00mm results in a 71.2% reduction in resin usage, while a 3.00mm wall thickness model achieves a substantial 16% reduction. These findings underscore the inverse relationship between model wall thickness and resin consumption, offering crucial insights for cost-effective and sustainable 3D printing practices in the dental industry. A comparative analysis of horizontal and vertical printing orientations clarify inherent differences. Horizontal printing takes 86.71 hours to produce 65 solid models, while vertical printing requires 91.65 hours. However, there is no significant difference in the time required for printing models horizontally or vertically, as the time is almost equivalent.

Conclusion:

The study emphasizes the importance of selecting optimal model wall thicknesses to balance material efficiency and aligner functionality for thermopressing on 3D printed models. It provides actionable insights for dental offices to enhance cost-effectiveness for in-office aligner production through informed material choices and printing strategies, contributing valuable data for effective in office aligner production