In vitro analysis of 3D-printed implant casts - how print orientation affects accuracy in full arch implant casts?

Sep 30, 2026

Upload by SANS

In vitro evaluation compares the accuracy of 3D-printed implant model casts for a complete edentulous arch produced with different print orientations. Acrylic resin mandibular models with implant analogs were scanned and aligned to create a reference geometry. Conventional open-tray splinted impressions and digital intraoral scanning generated implant casts, then 3D-printed casts were fabricated by digital light processing at 0°, 22.5°, 45°, 67.5°, and 90°. Linear (x/y/z and 3D) and angular discrepancies were measured and analyzed statistically, showing orientation and method effects on 3D accuracy, while angular discrepancies remained stable.

LanguageEnglish

CategoryResearch & Report

FormatPDF

Pages9

Reading Time23 min

AccessFree to download

Abstract

Purpose

Methods

Results

Conclusion

Introduction

Background and clinical relevance

Conventional vs digital workflows

Ezmek and Polat BMCOral Health (2026) 26:34 BMC Oral Health [https://doi.org/10.1186/s12903-025-07402-3](https://doi.org/10.1186/s12903-025-07402-3) RESEARCH Open Access In vitro analysis of 3D-printed implant casts: how print orientation affects accuracy in full arch implant casts? Bahadır Ezmek 1* and Büşra Polat2 Abstract Purpose This in vitro study evaluated the accuracy of 3D-printed implant model s of a complete edentulous arch with different print orientations (POs) . Methods An acrylic resin edentulous mandibular model provided with 4 straight multi-unit abutment (MUA) implant analogs was used. The model was scanned ten times using a desktop optical scanner (E4, 3Shape), and these scans were superimposed with the aid of reverse engineering (Geomagic Design X) to obtain a single reference cast for best representing the true geometry. Conventional impressions with open-tray splinted technique (n = 12) and digital impressions with an intraoral scanner (IOS) (Trios5, 3shape) (n = 12) were performed. The implant casts were designed using the IOS data (Model Designer, 3Shape) . 3D-printed implant casts were manufactured via a digital light processing printer at 0-, 22 . 5-, 45-, 67 . 5-, and 90 degrees of PO (n = 12) . Conventional and 3D-printed implant casts were scanned using the desktop optical scanner. The digital data of the scan bodies was superimposed on the casts. Virtual models were superimposed on reference data using metrology software (Geomagic Control X) . Linear discrepancies on the x-, y-, and z-axes, 3D discrepancies, and angular discrepancies were measured. Linear discrepancies in axes and overall linear discrepancies were evaluated via the Kruskal-Wallis test and post-hoc Dunn’s test. Angular discrepancies were assessed via one-way analysis of variance (ANOVA) and Tukey’s pairwise comparison tests. Results No significant differences were found in 3D or angular discrepancies between conventional models, IOS data, or 90-degree of PO (p >0. 05) . The angular deviations ofthe 0-degree PO group were not significantly different from the conventional, IOS, and the 90-degree PO groups (p >0. 05); however, the 3D discrepancies were higher in this group (p >0. 05) . The 3D discrepancies of the 90-degree PO group were significantly lower than those of the 0-, 45-, and 67 . 5-degree PO groups (p < 0. 05) . No significant difference was found in angular discrepancies between PO groups (p > 0. 05) . Conclusion IOS data are as accurate as conventional models. The highest accuracy of 3D-printed implant models can be obtained with 90 degrees of PO. PO does not influence the angular discrepancies of 3D-printed implant models. *Correspondence: Bahadır Ezmek [bahadir.ezmek@sbu.edu.tr](bahadir.ezmek@sbu.edu.tr) Full list of author information is available at the end of the article © The Author(s) 2025. Open Access This article is licensed under a Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 International License, which permits any non-commercial use, sharing, distribution and reproduction in any medium or format, as long as you give appropriate credit to the original author(s) and the source, provide a link to the Creative Commons licence, and indicate if you modified the licensed material. You do not have permission under this licence to share adapted material derived from this article or parts of it. The images or other third party material in this article are included in the article’s Creative Commons licence, unless indicated otherwise in a credit line to the material. If material is not included in the article’s Creative Commons licence and your intended use is not permitted by statutory regulation or exceeds the permitted use, you will need to obtain permission directly from the copyright holder. To view a copy of this licence, visit [http://creati](http://creati)[vecommons.org/l](vecommons.org/l)icenses/by-nc-nd/4.0/. Ezmek and Polat BMC Oral Health (2026) 26:34 Page 2 of 9

FAQs

What was the purpose of this in vitro study?

To evaluate the accuracy of 3D-printed implant model casts for a complete edentulous arch using different print orientations.

How were print orientations tested for the 3D-printed implant casts?

Casts were manufactured using a digital light processing printer at 0°, 22.5°, 45°, 67.5°, and 90° print orientation.

What conclusions were reached about accuracy and print orientation?

IOS data were as accurate as conventional models, the highest accuracy for 3D-printed models occurred at 90° print orientation, and print orientation did not influence angular discrepancies.

Sep 30, 2026

Upload by SANS