Digital versus conventional workflow for the fabrication of physical casts for fixed prosthodontics: A systematic review of accuracy

Intraoral scanners in implant prosthodontics. A narrative review

OBJECTIVES

To review the developments in intraoral scanner (IOS) technologies applied in implant prosthodontics, emphasizing their influence on the accuracy of digital impressions, occlusal registrations, and the fit of implant-supported restorations.

DATA

A collection of published articles related to implant prosthodontics, the accuracy of digital impressions, occlusal registration, and the fit of implant-supported fixed restorations.

SOURCES

Three search engines were selected: Medline/PubMed, EBSCO, and Cochrane. A manual search was also conducted.

STUDY SELECTION

A literature search screened relevant databases and journals for studies on IOS applications in digital implant prosthodontic workflows from Dec 2018 to Dec 2023. Inclusion criteria encompassed randomized control trials, clinical trials, case series, and in vitro research focused on the use of IOS in digital implant prosthodontics.

CONCLUSIONS

The increased utilization of digital dental technologies has led to significant integration of digital implant prosthodontic workflows into clinicians' clinical practice. Several variables affect the accuracy of digital impressions generated by IOS. Generally, the prevailing opinion in academic papers is that digital workflows are suitable for addressing short-span implant-supported restorations. However, when it comes to long-span defects, the accuracy of digital workflows is still a matter of debate. Digital bite registration is an integral part of the workflow. It depends mainly on the defect size and location, scan strategy, anatomical tooth variations, overbite and other factors. The overall fit of digitally prefabricated implant restorations comprises of proximal, occlusal contacts and how accurately the restoration connects with implants. Research methodologies need standardization for further validation.

CLINICAL SIGNIFICANCE

In clinical practice, it is essential to have a thorough and up-to-date comprehension of various factors that can affect the accuracy of digital impressions and the fit of the final prosthesis in implant prosthodontics.

Effect of 3D printing technology and print orientation on the trueness of additively manufactured definitive casts with different tooth preparations

OBJECTIVES

To evaluate the fabrication trueness of additively manufactured maxillary definitive casts with various tooth preparations fabricated with different 3-dimensional (3D) printers and print orientations.

METHODS

A maxillary typodont with tooth preparations for a posterior 3-unit fixed partial denture, lateral incisor crown, central incisor and canine veneers, first premolar and second molar inlays, and a first molar crown was digitized with an industrial scanner. This scan file was used to fabricate definitive casts with a digital light processing (DLP) or stereolithography (SLA) 3D printer in different orientations (0-degree, 30-degree, 45-degree, and 90-degree) (n = 7). All casts were digitized with the same scanner, and the deviations within each preparation site were evaluated. Generalized linear model analysis was used for statistical analysis (α = 0.05).

RESULTS

The interaction between the 3D printer and the print orientation affected measured deviations within all preparations (P ≤ 0.001) except for the lateral incisor crown and canine veneer (P ≥ 0.094), which were affected only by the main factors (P < 0.001). DLP-90 mostly led to the highest and DLP-0 mostly resulted in the lowest deviations within posterior tooth preparations (P ≤ 0.014). DLP-30 led to the lowest deviations within the first premolar inlay and DLP-45 led to the lowest deviations within the central incisor veneer preparation (P ≤ 0.045).

CONCLUSIONS

Posterior preparations of tested casts had the highest trueness with DLP-0 or DLP-30, while central incisor veneer preparations had the highest trueness with DLP-45. DLP-90 led to the lowest trueness for most of the tooth preparations.

CLINICAL SIGNIFICANCE

Definitive casts with tooth preparations fabricated with the tested DLP 3D printer and the print orientation adjusted on tooth preparation may enable well-fitting restorations. However, 90-degree print orientation should be avoided with this 3D printer, as it led to the lowest fabrication trueness.

Dimensional changes over time in stereolithographic models fabricated with a 3D printer

This study aimed to ascertain the effects of the shape of stereolithographic models fabricated with a three-dimensional (3D) printer and the use of different types of liquid resin on the dimensional changes of these models over time, to obtain valuable information for determining the period for which such models can be used following fabrication. Stereolithography models with the shape of a large truncated cone or a small truncated cone were fabricated using liquid resin as surgical guides (Group G) or master casts (Group M). (four groups in total, each n = 11). The shapes of all experimental specimens were measured immediately after fabrication and 1 day, 1 week, 2 weeks, 3 weeks, 4 weeks, 2 months, 3 months, 6 months, 1 year, and 1.5 years later. The shape data collected immediately after fabrication were taken as baseline data, and the dimensional changes over time at each timepoint were calculated. No significant change from 1 day to 1 year after fabrication was observed in any of the groups, but the change after 1.5 years was significantly larger than the changes at the other timepoints (p < 0.001). Significantly larger changes were evident in Group M than in Group G at all timepoints (p < 0.001). These results suggested that, from the viewpoint of dimensional stability over time, stereolithographic models should be used within 1 year of fabrication, and that the type of liquid resin used for stereolithographic model fabrication may affect how its dimensions change over time.

Positional accuracy of a single implant analog in additively manufactured casts in biobased model resin

OBJECTIVES

To evaluate the positional accuracy of implant analogs in biobased model resin by comparing them to that of implant analogs in model resin casts and conventional analogs in dental stone casts.

METHODS

Polyvinylsiloxane impressions of a partially edentulous mandibular model with a single implant were made and poured in type IV dental stone. The same model was also digitized with an intraoral scanner and additively manufactured implant casts were fabricated in biobased model resin (FotoDent biobased model) and model resin (FotoDent model 2 beige-opaque) (n = 8). All casts and the model were digitized with a laboratory scanner, and the scan files were imported into a 3-dimensional analysis software (Geomagic Control X). The linear deviations of 2 standardized points on the scan body used during digitization were automatically calculated on x-, y-, and z-axes. Average deviations were used to define precision, and 1-way analysis of variance and Tukey HSD tests were used for statistical analyses (α = 0.05).

RESULTS

Biobased model resin led to higher deviations than dental stone (all axes, P ≤ 0.031) and model resin (y-axis, P = 0.015). Biobased model resin resulted in the lowest precision of implant analog position (P ≤ 0.049). The difference in the positional accuracy of implant analogs of model resin and stone casts was nonsignificant (P ≥ 0.196).

CONCLUSIONS

Implant analogs in biobased model resin casts mostly had lower positional accuracy, whereas those in model resin and stone casts had similar positional accuracy. Regardless of the material, analogs deviated more towards mesial, while buccal deviations in additively manufactured casts and lingual deviations in stone casts were more prominent.

Influence of ambient light conditions on intraoral scanning: A systematic review

PURPOSE

To systematically assess the influence of ambient light on the accuracy and scanning time of intraoral scanning.

STUDY SELECTION

The present systematic review (CRD 42022346672) was registered at the International Prospective Register of Systematic Reviews (PROSPERO) and was performed based on the guidelines of the Preferred Reporting Items for Systematic Reviews and Meta-Analyses (PRISMA) 2020. Electronic searches were conducted using PubMed, Web of Science, and EMBASE, complemented by gray literature, references, and citations of the included studies. The primary outcome was accuracy, and the scanning time was a secondary outcome. Owing to the high heterogeneity, the pooled data were analyzed descriptively.

RESULTS

Six in vitro and two in vivo experiments were performed. Three in vitro studies reported both the accuracy and scanning time of the intraoral scans, whereas the remaining studies exclusively evaluated the accuracy. The studies mainly investigated the influence of illumination levels (0-11000 lux) on intraoral scanning. Intraoral scans revealed optimal accuracy at 1000-lux illumination for complete-arch dentition scans, whereas the influence of illumination levels on 4-unit or shorter scans was not clinically significant. The intraoral scans obtained using confocal microscopy were less affected by the illumination levels than those obtained using the active triangulation technique. Furthermore, the scanning time tended to increase with increasing illumination.

CONCLUSIONS

Evidently from the limited number of studies conducted, ambient light illumination had considerable influence on the accuracy and scanning time of intraoral scanning, which appeared to be related to the scanning range and imaging technology.

Conventional Dental Impressions vs. Impressions Reinforced with Rigid Mouthguards

The impression materials utilized today in dental medicine offer a good reproducibility and are easily accepted by patients. However, because they are polymer-based, they have issues regarding their dimensional stability. In this respect, the present work proposes a new type of dental impression, which is reinforced with rigid mouthguards. The aim of the study is to test the performances of such new impressions by comparing them to conventional ones-from this critical point of view, of the dimensional stability. Three types of polymeric materials were considered for both types of impressions: alginate, condensation silicone, and addition silicone. In order to obtain the new type of impressions, a manufacturing technique was developed, comprising the following phases: (i) conventional impressions were made; (ii) a plaster model was duplicated, and 15 rigid mouthguards were obtained; (iii) they were inserted in the impression technique, with each mouthguard positioned on the cast before the high-consistency material was inserted in the tray and the practitioner took the impression; (iv) the mouthguard remained in the tray and the low-viscosity material was inserted over the mouthguard; (v) the impression was positioned on the model, and after the material hardened, the mouthguard-reinforced impression was analyzed. In the evaluation of the dimensional stability, rigorous statistical analysis was essential to discern the performance differences between conventional and mouthguard-reinforced dental impressions. Statistical analyses employed non-parametric Mann-Whitney U tests because of the non-normal distribution of the data. They indicated a statistically significant improvement in the dimensional stability of addition silicone impressions when reinforced with mouthguards (p < 0.05), showcasing superior performance over conventional methods. Conversely, alginate and condensation silicone reinforced impressions did not exhibit the same level of stability improvement, suggesting the need for further optimization of these materials. In conclusion, from the three considered elastomers, addition silicone was found to be the prime candidate for high-precision dental impressions, with the potential to improve their quality from conventional impressions by utilizing the proposed reinforcing technique.

Influence of Intraoral Scanners, Operators, and Data Processing on Dimensional Accuracy of Dental Casts for Unsupervised Clinical Machine Learning: An In Vitro Comparative Study

Purpose

This study assessed the impact of intraoral scanner type, operator, and data augmentation on the dimensional accuracy of in vitro dental cast digital scans. It also evaluated the validation accuracy of an unsupervised machine-learning model trained with these scans.

Methods

Twenty-two dental casts were scanned using two handheld intraoral scanners and one laboratory scanner, resulting in 110 3D cast scans across five independent groups. The scans underwent uniform augmentation and were validated using Hausdorff's distance (HD) and root mean squared error (RMSE), with the laboratory scanner as reference. A 3-factor analysis of variance examined interactions between scanners, operators, and augmentation methods. Scans were divided into training and validation sets and processed through a pretrained 3D visual transformer, and validation accuracy was assessed for each of the five groups.

Results

No significant differences in HD and RMSE were found across handheld scanners and operators. However, significant changes in RMSE were observed between native and augmented scans with no specific interaction between scanner or operator. The 3D visual transformer achieved 96.2% validation accuracy for differentiating upper and lower scans in the augmented dataset. Native scans lacked volumetric depth, preventing their use for deep learning.

Conclusion

Scanner, operator, and processing method did not significantly affect the dimensional accuracy of 3D scans for unsupervised deep learning. However, data augmentation was crucial for processing intraoral scans in deep learning algorithms, introducing structural differences in the 3D scans. Clinical Significance. The specific type of intraoral scanner or the operator has no substantial influence on the quality of the generated 3D scans, but controlled data augmentation of the native scans is necessary to obtain reliable results with unsupervised deep learning.

Is a Wiggling-Motion Modified Two-Step Impression Technique as Accurate as Conventional Techniques in Restorative Dentistry?

BACKGROUND

The purpose of this study was to evaluate dental impression accuracy of one-step and two-step techniques compared to a modified two-step technique.

METHODS

Four impression techniques were compared: (1) a one-step double mix (DM) technique, (2) a cut-out (CO) technique, in which space relief was created using a blade and a laboratory bur, (3) a membrane (ME) technique, in which space relief was created by placing a PVC membrane on top of the putty material during the primary impression, and (4) a wiggling motion (WI) technique, in which PVC membrane was placed and additional wiggling movements were performed during the first 20 s when the primary impression was seated upon the master model (MM). Impressions were poured with type IV stone. Casts were scanned with a laboratory scanner and measurements were made for each cast using three-dimensional analysis software.

RESULTS

All groups presented differences compared to MM group, in at least one intra-abutment distance. Groups DM and ME presented the most significant differences, in three and two distances, respectively, whereas CO and WI presented one significant different distance compared to MM. There were no differences between MM and the four techniques for inter-abutment distances.

CONCLUSIONS

WI yielded similar results with CO technique. Both performed better than the other groups.

The Effect of Stacking on the Accuracy of 3D-Printed Full-Arch Dental Models

The objective of this study was to assess the effect of stacking on the dimensional and full-arch accuracy of 3D-printed models, utilising a standardised assessment methodology. A previously validated methodology involving a standard tessellation language image (STL) reference model, comprising seven spheres on a horseshoe base resembling a dental arch, was used. Six 3D-designed STL models were prepared, optimised, and stacked horizontally using 3D Sprint software. The stacking file was transferred to the NextDent 5100 printer to build the physical models. To assess accuracy, a coordinate measuring machine (CMM) measured the diameter of the spheres n=210, and twenty-one vectors extended between the centres of each of the seven spheres (n = 630). When compared to the reference model, significant differences were observed for dimensional (p = 0.006) and full-arch accuracy (p = 0.006) for all stacked models. Additionally, significant differences were observed between the stacked models for the dimensional accuracy between the posterior (p = 0.015), left posterior (p = 0.005) and anteroposterior (p = 0.002). The maximum contraction was observed in the fourth stacked model, which demonstrated the highest median deviation and least precision within the full-arch (MD = 666 μm, IQR = 55 μm), left posterior (MD = 136 μm, IQR = 12 μm), posterior (MD = 177 μm, IQR = 14 μm) and anteroposterior (MD = 179 μm, IQR = 16 μm) arch segments. In general, the anterior and left posterior arch segments recorded the highest contractions with a median deviation of 34 μm and 29 μm, and precision of 32 μm and 22 μm, respectively. Statistically significant differences were observed between the stacked models in terms of dimensional accuracy that were within clinically acceptable thresholds. The greatest contraction was noted in the fourth model, displaying the least full-arch accuracy compared to the other models. Stacked, additively manufactured, full arch models are a viable alternative for diagnostic, orthodontic, and single-unit prosthodontic applications. In contrast, caution should be exercised when utilising stacked models for full arch high accuracy prosthodontic applications. Further research is needed to assess the impact of additional variables including different printers and resins.

Additively Manufactured Scan Bodies for Virtual Patient Integration: Different Designs, Manufacturing Procedures, and Clinical Protocols

Additively manufactured intraoral scan bodies can be used to guide the alignment of a patient's digital file information, including facial and intraoral digital scans both with and without a cone beam computed tomography scan, and to obtain a 3D virtual patient's representation. The present manuscript reviews the different intraoral scan body designs, procedures involved in additive manufacturing, clinical protocols for fabricating an additively manufactured scan body, performing a patient's digital data collection, and completing the alignment techniques.

Effect of Different CAD/CAM Milling and 3D Printing Digital Fabrication Techniques on the Accuracy of PMMA Working Models and Vertical Marginal Fit of PMMA Provisional Dental Prosthesis: An In Vitro Study

Background: Minimal evidence exists on the efficacy of different digital manufacturing techniques in the fabrication of precise dental working models and provisional prosthesis. Aim of study: The objective was to evaluate the effect of two digital fabrication techniques (CAD/CAM milling and 3D printing) on the accuracy of PMMA working models and marginal fit of PMMA provisional prosthesis. Materials and methods: Two abutment teeth of modified typodont were prepared. A reference stone model was fabricated, and an optical impression was performed to obtain a CAD reference model. Four CAM milled working models and four printed working models were fabricated. CAD software was used to design the provisional prostheses. Group A tested four milled provisional prosthesis, and group B tested four 3D printed prosthesis. The 3D accuracy of working models was assessed by superimposition of the control reference working model on the CAD test working model. A stereo-optical microscope was used to assess vertical marginal fit of the provisional dental prosthesis. Student’s t and Mann–Whitney U tests were utilized to compare the two groups. Results: Results showed no statistically significant difference between the two tested groups. Conclusion: The two digital working model fabrication techniques recorded comparable accuracy. Similarly, 3D printed provisional prosthesis showed comparable marginal fit to the CAD/CAM milled ones.

A Comparison of Accuracy of Different Dental Restorative Materials between Intraoral Scanning and Conventional Impression-Taking: An In Vitro Study

The properties of underlying substrates influence the quality of an intraoral scan, but few studies have compared the outcomes using common restorative materials. In this study, we aimed to compare the accuracy of digital and conventional impressions recorded for four different dental materials as the substrates. Experimental crowns were produced with a metallic surface (gold or cobalt-chromium alloy (Co-Cr)) or without a metallic surface (zirconia or PMMA (polymethyl methacrylate)). A conventional impression was made in the conventional group (CON group), and gypsum models were subsequently scanned with a tabletop scanner. An intraoral scanner was used to scan the crowns either after applying a powder spray to reduce the surface reflectivity (IOS-P group) or without the powder spray (IOS group). The scans were assessed in three dimensions for precision and trueness. The accuracy did not differ between the CON and IOS groups for the non-metallic crowns. However, it was statistically different for the Co-Cr metallic crown, reducing trueness observed between groups as CON > IOS > IOS-P. The study evidences the differences in outer surface accuracy observed with a change in the substrate material to be imaged using an oral scanner and with the impression method. These findings suggest that the restoration material present in the oral cavity should be considered when selecting an impression-taking method.