The accuracy of orthodontic bracket placement is pivotal for effective treatment outcomes, and recent research highlights how 3D printing technology can be optimized to achieve this precision. A study conducted at the Affiliated Hospital of Jiangnan University examined the effect of various printing angles on bracket transfer models made using Polyvinyl Siloxane (PVS), providing important insights for orthodontic practices.
Released following the approval of its Medical Ethics Committee, the research began in October 2022 and aimed to determine the accuracy of 10 bracket transfer models printed at different angles: 0° without support, 0°, 45°, and 90° with support. Findings revealed significant differences tied to the printing angle, with the utmost precision realized at 90° with support structures.
Specifically, at the 90° angle, measurements indicated gaps of just 0.169 mm and 0.176 mm for the mesial and distal center points of the wings, respectively, showcasing a statistically significant level of accuracy (P < 0.05). Lower accuracy was observed when printing at the other angles, particularly at 0° without supports, where structural issues diminished the dimensional integrity of the wings.
Notably, the linear deviations for the 0° models were reported at 0.285 mm and 0.283 mm for groups A and B, respectively, indicating significant vertical discrepancies during bonding procedures (P < 0.001). This study underscored how minor errors can be particularly detrimental to treatment outcomes, necessitating continuous improvements to orthodontic processes.
3D printing offers substantial advantages over traditional manufacturing methods, including higher material utilization and cost reduction, revolutionizing dental applications. The advent of technologies such as Computer-Aided Design/Manufacturing (CAD/CAM) has propelled this field, making previously unachievable levels of precision attainable. 3D printing allows the customization of orthodontic trays, thereby facilitating accurate placements planned digitally.
The methodologies applied — including the use of intraoral scanners and the Medit T500 with 20 μm accuracy — were pivotal to the this study. The team’s innovative use of PVS reflected extensive clinical applications, aiding the successful fabrication of indirect bonding (IDB) trays through iterative, precise adjustments during digital planning periods. This reflects today’s shift toward digitization within orthodontics and emphasizes the need for accurate virtual modeling methods.
The significance of the printing angle became clear during the study. Researchers demonstrated through extensive data analysis and 3D measurements processed with dedicated software, how configurations directly influenced dimensional outcomes. Upon implementing varied printing angles, adherence to recommended bracket placements cited by the American Association of Orthodontists emerged as central, with maximum allowable deviations established at 0.5 mm.
discussions surrounding the potential integration of such precise models highlight the benefits across patient experiences. By minimizing errors during the bonding process, the incidence of necessary adjustments — often resulting in discomfort — is expected to decrease. Insights from this study reinforce the growing commitment to improve orthodontic accuracy and personalization via advanced manufacturing technologies.
While this research has established significant operational benchmarks, researchers are advocating for comprehensive longitudinal studies to validate these breakthroughs over time. Understanding how 3D-printed models perform under clinical conditions will be key to ensuring best practices persist and develop.
Conclusively, the investigation concludes 3D printing at specific angles, particularly utilizing supportive scaffolding at 90°, substantially enhances transfer model reliability. With the commercial and clinical potential of such innovations, orthopedic practitioners will benefit from precise tools as they strive to fulfill individualized patient care needs.