Zirconia crowns manufactured using digital light processing: Effects of build angle and layer thickness on the accuracy

Abstract

Objectives: This study investigated the effects of build angle and layer thickness on the trueness and precision of zirconia crowns manufactured using digital light processing (DLP) technology.

Materials and methods: Single crowns were fabricated from zirconia using DLP technology. The crowns were manufactured with three different representative build angles (0°, 45°, and 90°) and two different layer thicknesses (30 μm and 50 μm). After printing, the specimens were non-contact-scanned, and their accuracy was assessed using a 3D analysis software. Root mean square (RMS) values were used to determine trueness and precision. Color maps were generated to detect deviations within the specimens. Statistical analyses were conducted using two-way ANOVA.

Results: Build angle and layer thickness significantly affected trueness and precision (p < 0.05). At a 30-μm layer thickness, the crowns printed at angles of 0° (32.2 ± 3.2 μm) and 45° (33.9 ± 2.4 μm) demonstrated the best marginal trueness compared to those in other groups (p < 0.05). Notably, those printed at an angle of 90° exhibited the best intaglio surface trueness (37.4 ± 4.0 μm). At a 50-μm layer thickness, the crowns printed at an angle of 90° exhibited the lowest accuracy concerning marginal and intaglio surface aspects (27.7 ± 8.2 μm).

Conclusions: Both the build angle and layer thickness significantly affected the dimensional accuracy of DLP-printed zirconia crowns, with the 30-μm layer thickness offering superior trueness. Optimal results were achieved using build angles of 0° and 45° in conjunction with thinner layers, minimizing marginal defects.

Clinical significance: All zirconia crowns produced at different build angles and layer thicknesses satisfied clinical requirements. Specific combinations of these factors realized the fabrication of single crowns that possessed the highest accuracy.

Keywords: Accuracy; Additive manufacturing; Digital light processing; Precision; Trueness; Zirconia.