Effect of print orientation on the dimensional accuracy of three-dimensional-printed complete denture models: A comparative analysis of VAT photopolymerization and fused deposition modeling technologies

AIM To evaluate the effect of print orientation (0°, 45°, and 90°) on the dimensional accuracy, precision, and production parameters of three-dimensional (3D) printed complete denture models fabricated using VAT photopolymerization and fused deposition modeling (FDM) technologies.

SETTINGS AND DESIGN An in-vitro experimental comparative study was conducted to analyze orientation-dependent variations in dimensional trueness and precision among denture models fabricated with two additive manufacturing systems.

MATERIALS AND METHODS A complete denture prosthesis STL file was fabricated in 60 samples using VAT photopolymerization and FDM technologies across three orientations (0°, 45°, and 90°). Printed models underwent postprocessing, followed by digital superimposition to evaluate trueness and precision.

STATISTICAL ANALYSIS USED Statistical analyses were performed using one-way ANOVA with post hoc Tukey's honestly significant difference tests and independent t-tests for intertechnology comparison.

RESULTS VAT prints demonstrated higher average accuracy (mean deviation: 0.1106 mm) but greater variability (standard deviation [SD] =0.2448 mm) than FDM (mean deviation: 0.0316 mm, SD = 0.1558 mm). Across both technologies, the 0° orientation showed the least deviation (VAT: 0.1106 mm and FDM: 0.0316 mm). ANOVA indicated no significant differences among orientations (P = 0.109), whereas t-tests revealed substantial differences between technologies (t = 16.46, P < 0.00001). FDM at 90° exhibited the lowest variability (SD = 0.1163 mm), suggesting a trend toward improved consistency, though this did not reach statistical significance.

CONCLUSION Print orientation influenced dimensional accuracy trends, but only technology type showed statistically significant differences. VAT photopolymerization is suitable for high-precision applications.