Influence of the three-dimensional printing technique and printing layer thickness on model accuracy

OBJECTIVE

The accuracies of three-dimensional (3D) printed dental models using various digital light processing (DLP) and stereolithography (SLA) printers at different thicknesses were compared.

MATERIALS AND METHODS

Based on digital dental models (originally digitized using R700; 3Shape, Copenhagen, Denmark), physical dental models were printed using three types of DLP printers: (1) EvoDent (UnionTec, Shanghai, China) with layer thicknesses of 50 μm and 100 μm; (2) EncaDent (Encashape, WuXi, China) with layer thicknesses of 20, 30, 50 and 100 μm; (3) Vida HD (Envisioned, Dearborn, MI, USA) with layer thicknesses of 50 and 100 μm. Models with the SLA printer Form 2 (Formlabs, Somerville, MA, USA) were printed with layer thicknesses of 25, 50 and 100 μm. All 22 printed models were converted to digital dental models using a D2000 model scanner (3 Shape, Copenhagen, Denmark) and compared three-dimensionally to the source files using Geomagic Qualify 12.0 (3D Systems, Rock Hill, SC, USA).

RESULTS

The printing accuracy of all printers was higher at 50 μm. When the layer thickness was set at 100 μm, the printing speed and printing accuracy of DLP printer were both superior to those of the SLA printer. In all groups, the EvoDent 50 μm group had the highest consistency with the source files (mean absolute deviation of 0.0233 mm in the maxilla and 0.0301 mm in the mandible). While the accuracy of Form 2 100 μm group was the lowest (mean absolute deviation of 0.0511 mm in the maxilla and 0.0570 mm in the mandible).

CONCLUSION

For the 3D printers studied, 50 μm was the optimum layer thickness for DLP technology, and the printing accuracy using SLA technology increased with decreasing layer thickness. The DLP technology also had higher printing accuracy at a layer thickness of 100 μm. EvoDent 50 μm had the highest and Form 2 100 μm the lowest printing accuracy.

Digital Light Processing Based Three-dimensional Printing for Medical Applications

An additive manufacturing technology based on projection light, digital light processing (DLP), three-dimensional (3D) printing, has been widely applied in the field of medical products production and development. The precision projection light, reflected by a digital micromirror device of million pixels instead of one focused point, provides this technology both printing accuracy and printing speed. In particular, this printing technology provides a relatively mild condition to cells due to its non-direct contact. This review introduces the DLP-based 3D printing technology and its applications in medicine, including precise medical devices, functionalized artificial tissues, and specific drug delivery systems. The products are particularly discussed for their significance in medicine. This review indicates that the DLP-based 3D printing technology provides a potential tool for biological research and clinical medicine. While, it is faced to the challenges of scale-up of its usage and waiting period of regulatory approval.

Light-based 3D bioprinting of bone tissue scaffolds with tunable mechanical properties and architecture from photocurable silk fibroin

Three-dimensional (3D) bioprinting based on digital light processing (DLP) offers unique opportunities to prepare scaffolds that mimic the architecture and biomechanical properties of human tissues. Limited availability of biocompatible and biodegradable bioinks amenable for DLP-bioprinting is an impediment in this field. This study presents a bioink prepared from silk fibroin (SF) tailored for DLP bioprinting. Photocurable methacrylated-SF (SF-MA) was synthesized with 67.3% of methacrylation. Physical characterization of rheological and mechanical properties revealed that the 3D printed hydrogels of SF-MA (spanning from 10 to 25 wt%) exhibit bone tissue-like viscoelastic behavior and compressive modulus ranging from ≈12 kPa to ≈96 kPa. The gels exhibited favorable degradation (≈48 to 91% in 21 days). This SF-MA bioink afforded the printing of complex structures, with high precision. Pre-osteoblasts were successfully encapsulated in 3D bioprinted SF-MA hydrogels with high viability. 15% SF-MA DLP bioprinted hydrogels efficiently supported cell proliferation with favorable cell morphology and cytoskeletal organization. A progressive increase in cell-mediated calcium deposition up to 14 days confirmed the ability of the gels to drive osteogenesis, which was further augmented by soluble induction factors. This work demonstrates the potential of silk fibroin-derived bioinks for DLP-based 3D bioprinting of scaffolds for tissue engineering.

Comparing accuracy of denture bases fabricated by injection molding, CAD/CAM milling, and rapid prototyping method

PURPOSE

The accuracy of denture bases was compared among injection molding, milling, and rapid prototyping (RP) fabricating method.

MATERIALS AND METHODS

The maxillary edentulous master cast was fabricated and round shaped four notches were formed. The cast was duplicated to ten casts and scanned. In the injection molding method, designed denture bases were milled from a wax block and fabricated using SR Ivocap injection system. Denture bases were milled from a pre-polymerized block in the milling method. In the RP method, denture bases were printed and post-cured. The intaglio surface of the base was scanned and surface matching software was used to measure inaccuracy. Measurements were performed between four notches and two points in the mid-palatal suture to evaluate inaccuracy. The palatine rugae resolution was evaluated. One-way analysis of variance was used for statistical analysis at α=.05.

RESULTS

No statistically significant differences in distances among four notches (P>.05). The accuracy of the injection molding method was lower than those of the other methods in two points of the mid-palatal suture significantly (P<.05). The degree of palatine rugae resolution was significantly higher in the injection molding method than that in other methods (P<.05).

CONCLUSION

The overall accuracy of the denture base is higher in milling and RP method than the injection molding method. The degree of fine reproducibility is higher in the injection molding method than the milling or RP method.

High-resolution lithographic biofabrication of hydrogels with complex microchannels from low-temperature-soluble gelatin bioresins

Biofabrication via light-based 3D printing offers superior resolution and ability to generate free-form architectures, compared to conventional extrusion technologies. While extensive efforts in the design of new hydrogel bioinks lead to major advances in extrusion methods, the accessibility of lithographic bioprinting is still hampered by a limited choice of cell-friendly resins. Herein, we report the development of a novel set of photoresponsive bioresins derived from ichthyic-origin gelatin, designed to print high-resolution hydrogel constructs with embedded convoluted networks of vessel-mimetic channels. Unlike mammalian gelatins, these materials display thermal stability as pre-hydrogel solutions at room temperature, ideal for bioprinting on any easily-accessible lithographic printer. Norbornene- and methacryloyl-modification of the gelatin backbone, combined with a ruthenium-based visible light photoinitiator and new coccine as a cytocompatible photoabsorber, allowed to print structures resolving single-pixel features (∼50 ​μm) with high shape fidelity, even when using low stiffness gels, ideal for cell encapsulation (1-2 ​kPa). Moreover, aqueous two-phase emulsion bioresins allowed to modulate the permeability of the printed hydrogel bulk. Bioprinted mesenchymal stromal cells displayed high functionality over a month of culture, and underwent multi-lineage differentiation while colonizing the bioresin bulk with tissue-specific neo-deposited extracellular matrix. Importantly, printed hydrogels embedding complex channels with perfusable lumen (diameter <200 ​μm) were obtained, replicating anatomical 3D networks with out-of-plane branches (i.e. brain vessels) that cannot otherwise be reproduced by extrusion bioprinting. This versatile bioresin platform opens new avenues for the widespread adoption of lithographic biofabrication, and for bioprinting complex channel-laden constructs with envisioned applications in regenerative medicine and hydrogel-based organ-on-a-chip devices.

Anti-biofilm multi drug-loaded 3D printed hearing aids

Over 5% of the world's population has disabling hearing loss, which affects approximately one third of individuals over 65 years. Hearing aids are commonly used in this population group, but prolonged use of these devices may cause ear infections. We describe for the first time, the use of 3D printing to fabricate hearing aids loaded with two antibiotics, ciprofloxacin and fluocinolone acetonide. Digital light processing 3D printing was employed to manufacture hearing aids from two polymer resins, ENG hard and Flexible. The inclusion of the antibiotics did not affect the mechanical properties of the hearing aids. All multi-drug-loaded devices exhibited a hydrophilic surface, excellent blood compatibility and anti-biofilm activity against P. aeruginosa and S. aureus. Hearing aids loaded with ciprofloxacin (6% w/w) and fluocinolone acetonide (0.5% w/w) sustained drug release for more than two weeks and inhibited biofilm formation on the surface of the devices and bacteria growth in the surrounding medium. In summary, this work highlights the potential of vat photopolymerization 3D printing as a versatile manufacturing approach to fabricate high-fidelity patient-specific medical devices with anti-bacterial properties.

Zirconia toughened hydroxyapatite biocomposite formed by a DLP 3D printing process for potential bone tissue engineering

The construction of ceramic components with UV curing is a developing trend by an additive manufacturing (AM) technology, due to the excellent advantages of high precision selective fixation and rapid prototyping, the application of this technology to bone defect repair had become one of the hotspots of research. Hydroxyapatite (HAP) is one of the most popular calcium phosphate biomaterials, which is very close to the main ingredient of human bones. Thus, hydroxyapatite biomaterials are popular as bone graft materials. In summary, the preparation of HAP bioceramics by a 3D printing of digital light processing (DLP) is a promising work. However, the preparation of HAP hybrid suspensions with high solid loading and good fluidity that can be printed by DLP encountered some challenges. Therefore, the purpose of this work is to improve and develop a novel UV-curing suspension with a high solids loading, which the suspension with the hydrodynamic properties and stability are suitable for DLP printer, in order to compensate for the brittleness of HAP ceramics itself to a certain extent, a low amount of zirconia was added in the suspension as an additive to fabricate a zirconia toughened HAP bioceramic composite by a DLP of 3D printing. In this work, the HAP powder was pre-modified by two organic modifiers to improve the compatibility in the acrylic resin system, and the addition of the castor oil phosphate further reduced the shear stress of the suspension to ensure strong liquidity. The UV suspension with 60 wt% powder particle loading had a minimum viscosity of 7495 mPa·s at 30 rpm, which was vacuum sintered at 1100 °C, 1200 °C, and 1250 °C, respectively. The composite ceramics (with 6 wt% ZrO₂) at 1200 °C had a relative density of 90.7%, while the sintered samples at 1250 °C had stronger tensile strength and bending strength. The toughening effect of zirconia incorporation on HAP ceramics was also confirmed by the change of tensile modulus and bending modulus, whereas the corresponding mechanical properties were also significantly enhanced.

Direct 3D printing of monolithic ion exchange adsorbers

Monolithic adsorbers with anion exchange (AEX) properties have been 3D printed in an easy one-step process, i.e. not requiring post-functionalization to introduce the AEX ligands. The adsorber, 3D printed using a commercial digital light processing (DLP) printer, was obtained by copolymerisation of a bifunctional monomer bearing a positively charged quaternary amine as well as an acrylate group, with the biocompatible crosslinker polyethylene glycol diacrylate (PEGDA). To increase the surface area, polyethylene glycol was introduced into the material formulation as pore forming agent. The influence of photoinitiator (Omnirad 819) and photoabsorber (Reactive Orange 16, RO16) concentration was investigated in order to optimize printing resolution, allowing to reliably 3D print features as small as 200 μm and of highly complex Schoen Gyroids. Protein binding was measured on AEX adsorbers with a range of ligand densities (0.00, 2.03, 2.60 and 3.18 mmol/mL) using bovine serum albumin (BSA) and c-phycocyanin (CPC) as model proteins. The highest equilibrium binding capacity was found for the material presenting the lowest ligand density analysed (2.03 mmol/mL), adsorbing 73.7 ± 5.9 mg/mL and 38.0 ± 2.2 mg/mL of BSA and CPC, respectively. This novel 3D printed material displayed binding capacities in par or even higher than commercially available chromatographic resins. We expect that the herein presented approach of using bifunctional monomers, bearing commonly used chromatography ligands, will help overcome the material limitations currently refraining 3D printing applications in separation sciences.

Elution behavior of a 3D-printed, milled and conventional resin-based occlusal splint material

OBJECTIVE

The elution of unpolymerized (co-)monomers and additives from methacrylic resin-based materials like polymethyl methacrylate (PMMA) can cause adverse side effects, such as mutagenicity, teratogenicity, genotoxicity, cytotoxicity and estrogenic activity. The aim of this study was to quantify the release and the cytotoxicity of residual (co-)monomers and additives from PMMA-based splint materials under consideration of real splint sizes. Three different materials used for additive (3D printing), subtractive (milling) and conventional (powder and liquid) manufacturing were examined.

METHODS

The splint materials SHERAprint-ortho plus (additive), SHERAeco-disc PM20 (subtractive) and SHERAORTHOMER (conventional) were analysed. 16 (n = 4) sample discs of each material (6 mm diameter and 2 mm height) were polished on the circular and one cross-section area and then eluted in both distilled water and methanol. The discs were incubated at 37 °C for 24 h or 72 h and subsequently analysed by gas chromatography/mass spectrometry (GC/MS) for specifying and quantifying released compounds. XTT-based cell viability assays with human gingival fibroblasts (HGFs) were performed for Tetrahydrofurfuryl methacrylate (THFMA), 1,4-Butylene glycol dimethacrylate (BDDMA) and Tripropylenglycol diacrylate (TPGDA). In order to project the disc size to actual splint sizes in a worst-case scenario, lower and upper jaw occlusal splints were designed and volumes and surfaces were measured.

RESULTS

For SHERAeco-disc PM20 and for SHERAORTHOMER no elution was determined in water. SHERAprint-ortho plus eluted the highest THFMA concentration of 7.47 μmol/l ±2,77 μmol/l after 72 h in water. Six (co-)monomers and five additives were detected in the methanol eluates of all three materials tested. The XTT-based cell viability assays resulted in a EC₅₀ of 3006 ± 408 μmol/l for THFMA, 2569.5 ± 308 μmol/l for BDDMA and 596.7 ± 88 μmol/l for TPGDA.

SIGNIFICANCE

With the solvent methanol, released components from the investigated splint materials exceeded cytotoxic concentrations in HGFs calculated for a worst-case scenario in splint size. In the water eluates only the methacrylate THFMA could be determined from SHERAprint-ortho plus in concentrations below cytotoxic levels in HGFs.

DLP printed hDPSC-loaded GelMA microsphere regenerates dental pulp and repairs spinal cord

Dental pulp regeneration is ideal for irreversible pulp or periapical lesions, and in situ stem cell therapy is one of the most effective therapies for pulp regeneration. In this study, we provided an atlas of the non-cultured and monolayer cultured dental pulp cells with single-cell RNA sequencing and analysis. Monolayer cultured dental pulp cells cluster more closely together than non-cultured dental pulp cells, suggesting a lower heterogeneous population with relatively consistent clusters and similar cellular composition. We successfully fabricated hDPSC-loaded microspheres by layer-by-layer photocuring with a digital light processing (DLP) printer. These hDPSC-loaded microspheres have improved stemness and higher multi-directional differentiation potential, including angiogenic, neurogenic, and odontogenic differentiation. The hDPSC-loaded microspheres could promote spinal cord regeneration in rat spinal cord injury models. Moreover, in heterotopic implantation tests on nude mice, CD31, MAP2, and DSPP immunofluorescence signals were observed, implying the formation of vascular, neural, and odontogenetic tissues. In situ experiments in minipigs demonstrated highly vascularized dental pulp and uniformly arranged odontoblast-like cells in root canals of incisors. In short, hDPSC-loaded microspheres can promote full-length dental pulp regeneration at the root canals' coronal, middle, and apical sections, particularly for blood vessels and nerve formation, which is a promising therapeutic strategy for necrotic pulp.

Ink Material Selection and Optical Design Considerations in DLP 3D Printing

Digital light processing (DLP) 3D printing has become a powerful manufacturing tool for the fast fabrication of complex functional structures. The rapid progress in DLP printing has been linked to research on optical design factors and ink selection. This critical review highlights the main challenges in the DLP printing of photopolymerizable inks. The kinetics equations of photopolymerization reaction in a DLP printer are solved, and the dependence of curing depth on the process optical parameters and ink chemical properties are explained. Developments in DLP platform design and ink selection are summarized, and the roles of monomer structure and molecular weight on DLP printing resolution are shown by experimental data. A detailed guideline is presented to help engineers and scientists to select inks and optical parameters for fabricating functional structures for multi-material and 4D printing applications.

Nano-Hydroxyapatite Bone Scaffolds with Different Porous Structures Processed by Digital Light Processing 3D Printing

The morphologies and structures of the scaffold have a significant influence on their mechanical and biological properties. In this work, different types of porous structures: Triply periodic minimal surface-Schwarz primitive (P), body-centered cubic, and cubic pore-shaped (CPS) hydroxyapatite scaffolds with ~70% porosity were fabricated through digital light processing (DLP) 3D printing technology. The compressive properties and in vitro cell evaluations such as cell proliferation and attachment morphology of these scaffolds were systematically compared. The results showed that the CPS scaffolds exhibited the highest compressive strength (~22.5 MPa) and modulus (~400 MPa). In addition, the CPS scaffolds also performed the most active cell metabolisms as compared to other two structures, which may account for the larger pore size and smaller curvature of the substrate. This study provides a general guidance for the fabrication and selection of porous bone scaffolds processed by DLP 3D printing.

An In Vitro Evaluation of the Effect of 3D Printing Orientation on the Accuracy of Implant Surgical Templates Fabricated By Desktop Printer

PURPOSE

To evaluate the effect of different 3D printing orientations on internal and seating accuracy of implant surgical templates fabricated by a digital light processing (DLP) printer.

MATERIALS AND METHODS

A single maxillary model with a missing central incisor was used to design a surgical template for single implant placement. According to the printing orientation, three surgical template groups were included in the study: horizontal (H), angled (A) and vertical (V) (n = 10). For the H group, the templates were produced parallel to the printing platform, while for the V group, the templates were perpendicular to the platform. The A group templates had a 45° angle orientation to the platform. Each template was scanned at the fitting surface and after seating on the master model. The internal accuracy involved measuring the trueness and precision of the internal surface, while for the seating accuracy, the vertical discrepancy after seating the template was measured. To determine the difference among the groups, ANOVA test was applied followed by Tukey post hoc tests (α = 0.05).

RESULTS

The H group had the lowest internal surface inaccuracy (trueness = 100.7 μm; precision = 69.1 μm) followed by A (trueness = 114.0 μm; precision = 77.3 μm) and V (trueness = 120.3 μm; precision = 82.4 μm) groups, respectively (p < 0.001). Similarly, the H group had the most superior seating accuracy (543.8 μm) followed by A group (1006.0 μm) and V group (1278.0 μm), respectively (p < 0.001).

CONCLUSIONS

The orientation of 3D printing of implant surgical templates fabricated by the DLP desktop printer influenced the accuracy of the templates. The horizontally printed templates consistently exhibited superior accuracy. To reduce deviation of implant placement, it is recommended to print the surgical templates with their largest dimension parallel to the printing platform.

Development of hierarchical porous bioceramic scaffolds with controlled micro/nano surface topography for accelerating bone regeneration

Mimicking hierarchical porous architecture of bone has been considered as a valid approach to promote bone regeneration. In this study, hierarchical porous β-tricalcium phosphate (β-TCP) scaffolds were constructed by combining digital light processing (DLP) printing technique and in situ growth crystal process. Macro/micro hierarchical scaffolds with designed macro pores for facilitating the ingrowth of bone tissue were fabricated by DLP printing. Three types of micro/nano surface topography were obtained by in situ growth crystal process to regulate stem cells behavior. The attachment and proliferation of rat bone marrow mesenchymal stem cells (rBMSCs) were strongly dependent on the surface roughness and the specific surface area. The micro/nano surface topography distinctly facilitated the differentiation of rBMSCs by targeting MAPK, STAT and AKT signaling pathways, in which the sodium hydroxide treatment group showed the highest promoting effect. Furthermore, in vivo results of skull defect repair model of rats indicated that hierarchical scaffolds with micro/nano topographies exhibited appealing bone regeneration capacity. The hierarchical porous bioceramic scaffolds constructed by integrating structural design and physical stimulation of the external surface topography have great potential for rapid bone repair via modulation of microenvironmental regulatory pathways at the bone defect site.

3D bioprinting of corneal decellularized extracellular matrix: GelMA composite hydrogel for corneal stroma engineering

Millions of individuals across the world suffer from corneal stromal diseases that impair vision. Fortunately, three-dimensional (3D) bioprinting technology which has revolutionized the field of regenerative tissue engineering makes it feasible to create personalized corneas. In this study, an artificial cornea with a high degree of precision, smoothness, and programmable curvature was prepared by using digital light processing (DLP) 3D bioprinting in one piece with no support structure, and the construct was then confirmed by optical coherence tomography (OCT). On the basis of this approach, we developed a novel corneal decellularized extracellular matrix/gelatin methacryloyl (CECM-GelMA) bioink that can produce complex microenvironments with highly tunable mechanical properties while retaining high optical transmittance. Furthermore, the composite hydrogel was loaded with human corneal fibroblasts (hCFs), and in vitro experiments showed that the hydrogel maintained high cell viability and expressed core proteins. In vivo tests revealed that the hydrogel might promote epithelial regeneration, keep the matrix aligned, and restore clarity. This demonstrates how crucial a role CECM plays in establishing a favorable environment that encourages the transformation of cell function. Therefore, artificial corneas that can be rapidly customized have a huge potential in the development of in vitro corneal matrix analogs.

Three-dimensional printing of gyroid-structured composite bioceramic scaffolds with tuneable degradability

Customisation of bioactivity and degradability of porous bioceramic scaffolds is a formidable challenge in the field of regenerative medicine. In this study, we developed gyroid-structured ternary composite scaffolds (biphasic calcium phosphate (BCP) and 45S5 bioglass® (BG)) using digital light processing 3D printing technology based on material and structural design. Additionally, the mechanical strength, bioactivity, degradability, and biocompatibility of the composite ceramic scaffolds were evaluated. The results revealed that BG reacted with BCP to generate major active crystalline phases of CaSiO₃ and Na₃Ca₆(PO₄)₅. These active crystalline phases accelerated the exchange rate of Si⁴⁺, Ca²⁺, and PO₄^3- with HCO^3- in simulated body fluids and resulted in the rapid formation of carbonated hydroxyapatite (CHA), analogous to the formation of natural bone tissue. Interestingly, the precipitated CHA showed petal- and needle-like morphologies, which provided a large surface area to promote cell adhesion and proliferation. Furthermore, an increase in the BG content improved the degradability of ternary composite scaffolds after soaking in Tris-HCl solution. The tuneable degradability increased by three times at 30 wt% BG and sharply increased by 6.8 times at 40 wt% BG. This study provides a promising strategy to design scaffolds with improved bioactivity and tuneable degradability to assist a diverse population suffering from orthopedic conditions.

In-hospital professional production of patient-specific 3D-printed devices for hand and wrist rehabilitation

The reported use of 3D printing in hand and wrist rehabilitation has been mostly limited to feasibility studies and case series so far. Some of the reasons are the lack of purpose-built scanning applications, complicated digital design software, and lengthy and error-prone printing processes. We propose a multidisciplinary workflow for in-hospital mass production of patient-specific 3D-printed devices for hand and wrist rehabilitation.

Effect of build orientation and layer thickness on manufacturing accuracy, printing time, and material consumption of 3D printed complete denture bases

OBJECTIVES

To evaluate the influence of build orientation and layer thickness on manufacturing accuracy, material consumption, and printing time of complete denture (CD) bases fabricated using digital light processing (DLP).

METHODS

The CD base was designed on the basis of a standard maxillary edentulous model. Seventy CD bases were fabricated using a DLP 3D printer (Pro95, SprintRay, USA) and printable CD base material (DENTCA Denture Base II, Dentca, USA) at seven build orientations (0°, labial 45°, labial 90°, posterior 45°, posterior 90°, buccal 45°, and buccal 90°) and two types of layer thicknesses (50- and 100 μm) (n = 5). All test CD bases were digitalized and superimposed on the reference cast by section-based best-fit alignment. For evaluating manufacturing accuracy, deviation analysis was performed to compare the test data with the reference cast using the "3D Compare" in the 3D metrology software. The printing time and material consumption were calculated using slicing software and recorded, respectively. The two-way ANOVA test was used for accuracy evaluation, and the non-parametric test was used to evaluate printing time and material consumption (α = 0.05).

RESULTS

Statistically significant differences were found in the manufacturing accuracy (p < 0.001), printing time (p < 0.001), and material consumption (p < 0.001) among the build orientation groups. The labial 45° and labial 90° groups showed the best accuracy. The 90° build orientations required the least material consumption and longest printing time; the labial 45° group consumed the most printing materials; the 0° group required the shortest printing time to fabricate a CD base. Moreover, the layer thickness influenced the printing time (p < 0.001) rather than the accuracy (p = 0.560) and material consumption (p = 1.000).

CONCLUSIONS

When DLP was used to fabricate the CD bases, the build orientation influenced the manufacturing accuracy, material consumption, and printing time. However, the layer thickness only affected the printing time.

CLINICAL SIGNIFICANCE

This study suggests that optimizing the build orientation can improve the manufacturing accuracy and reduce the material consumption and printing time of a DLP-printed CD base. The fast-printing setting (100 μm layer thickness) can reduce the printing time without compromising the manufacturing accuracy of the CD base.

Evaluation of the marginal and internal fit of a single crown fabricated based on a three-dimensional printed model

PURPOSE

To evaluate the fit of a crown produced based on a 3D printed model and to investigate its clinical applicability.

MATERIALS AND METHODS

A master die was fabricated with epoxy. Stone dies were fabricated from conventional impressions (Conventional stone die group: CS, n=10). Digital virtual dies were fabricated by making digital impressions (Digital Virtual die group: VD, n=10). 3D data obtained from the digital impression was used to fabricate 3D printed models (DLP die group: DD, n=10, PolyJet die group: PD, n=10). A total of 40 crowns were fabricated with a milling machine, based on CS, VD, DD and PD. The inner surface of all crowns was superimposed with the master die files by the “Best-fit alignment” method using the analysis software. One-way and 2-way ANOVA were performed to identify significant differences among the groups and areas and their interactive effects (α=.05). Tukey's HSD was used for post-hoc analysis.

RESULTS

One-way ANOVA results revealed a significantly higher RMS value in the 3D printed models (DD and PD) than in the CS and DV. The RMS values of PD were the largest among the four groups. Statistically significant differences among groups (P<.001) and between areas (P<.001) were further revealed by 2-way ANOVA.

CONCLUSION

Although the fit of crowns fabricated based on the 3D printed models (DD and PD) was inferior to that of crowns prepared with CS and DV, the values of all four groups were within the clinically acceptable range (<120 µm).

Evaluating the accuracy (trueness and precision) of interim crowns manufactured using digital light processing according to post-curing time: An in vitro study

PURPOSE

This study aimed to compare the accuracy (trueness and precision) of interim crowns fabricated using DLP (digital light processing) according to post-curing time.

MATERIALS AND METHODS

A virtual stone study die of the upper right first molar was created using a dental laboratory scanner. After designing interim crowns on the virtual study die and saving them as Standard Triangulated Language files, 30 interim crowns were fabricated using a DLP-type 3D printer. Additively manufactured interim crowns were post-cured using three different time conditions-10-minute post-curing interim crown (10-MPCI), 20-minute post-curing interim crown (20-MPCI), and 30-minute post-curing interim crown (30-MPCI) (n = 10 per group). The scan data of the external and intaglio surfaces were overlapped with reference crown data, and trueness was measured using the best-fit alignment method. In the external and intaglio surface groups (n = 45 per group), precision was measured using a combination formula exclusive to scan data (₁₀C₂). Significant differences in accuracy (trueness and precision) data were analyzed using the Kruskal-Wallis H test, and post hoc analysis was performed using the Mann-Whitney U test with Bonferroni correction (α=.05).

RESULTS

In the 10-MPCI, 20-MPCI, and 30-MPCI groups, there was a statistically significant difference in the accuracy of the external and intaglio surfaces (P <.05). On the external and intaglio surfaces, the root mean square (RMS) values of trueness and precision were the lowest in the 10-MPCI group.

CONCLUSION

Interim crowns with 10-minute post-curing showed high accuracy.

Effect of rinsing time on the accuracy of interim crowns fabricated by digital light processing: An in vitro study

PURPOSE

This study was to evaluate the effect of rinsing time on the accuracy of interim crowns fabricated by digital light processing.

MATERIALS AND METHODS

The maxillary right first molar master die was duplicated using a silicone material, while a study die was produced using epoxy resin. Scans of the epoxy resin die were used in combination with CAD software to design a maxillary right first molar interim crown. Based on this design, 24 interim crowns were fabricated with digital light processing. This study examined the trueness and precision of products that were processed with one of the three different postprocessing rinsing times (1 min, 5 min, and 10 min). Trueness was measured by superimposing reference data with scanned data from external, intaglio, and marginal surfaces. Precision was measured by superimposing the scan data within the group. The trueness and precision data were analyzed using Kruskal-Wallis, nonparametric, and post-hoc tests, and were compared using a Mann-Whitney U test with Bonferroni correction (α=.05).

RESULTS

The trueness of the external and intaglio surfaces of crowns varied significantly among the different rinsing times (P =.004, P =.003), but there was no statistically significant difference in terms of trueness measurements of the marginal surfaces (P =.605). In terms of precision, statistically significant differences were found among the external, intaglio, and marginal surfaces (P =.001).

CONCLUSION

Interim crowns rinsed for 10 minutes showed high accuracy.

Matching mechanical heterogeneity of the native spinal cord augments axon infiltration in 3D-printed scaffolds

Scaffolds delivered to injured spinal cords to stimulate axon connectivity often match the anisotropy of native tissue using guidance cues along the rostral-caudal axis, but current approaches do not mimic the heterogeneity of host tissue mechanics. Although white and gray matter have different mechanical properties, it remains unclear whether tissue mechanics also vary along the length of the cord. Mechanical testing performed in this study indicates that bulk spinal cord mechanics do differ along anatomical level and that these differences are caused by variations in the ratio of white and gray matter. These results suggest that scaffolds recreating the heterogeneity of spinal cord tissue mechanics must account for the disparity between gray and white matter. Digital light processing (DLP) provides a means to mimic spinal cord topology, but has previously been limited to printing homogeneous mechanical properties. We describe a means to modify DLP to print scaffolds that mimic spinal cord mechanical heterogeneity caused by variation in the ratio of white and gray matter, which improves axon infiltration compared to controls exhibiting homogeneous mechanical properties. These results demonstrate that scaffolds matching the mechanical heterogeneity of white and gray matter improve the effectiveness of biomaterials transplanted within the injured spinal cord.

Effect of phytochemical-filled microcapsules with antifungal activity on material properties and dimensional accuracy of denture base resin for three-dimensional printing

BACKGROUND

Studies on the material properties and dimensional accuracy of three-dimensionally (3D) printed denture base containing microcapsules with antifungal phytochemicals are lacking.

METHODS

Two types of phytochemicals (phytoncide A and B) with antifungal activity were microencapsulated. The 3D-printed denture base specimens with minimum and maximum effective concentrations of microcapsules (6 and 8 wt% for phytoncide A; 15 and 25 wt% for phytoncide B) were prepared. The morphological changes of C. albicans on 3D-printed denture base with microcapsules was microscopically observed. The degree of conversion of 3D-printed denture base with microcapsules investigated. The microhardness and flexural strength values were also measured to evaluate the mechanical properties of 3D-printed denture bases. The dimensional accuracy (trueness) of the specimens with microcapsules was measured as root-mean-square values (RMS) for the whole, upper, and side surfaces of the specimens as well as their total height. For the degree of conversion, microhardness, and flexural strength values, the Kruskal-Wallis analysis and a post-hoc comparison using Mann-Whitney U test was performed. For the analysis of trueness (RMS), the one-way analysis of variance and a post-hoc comparison using Tukey's method was conducted (α = 0.05).

RESULTS

At both maximum and minimum effective concentrations of microcapsules, cell surface disruption or membrane breakdown of fungal cells were observed in the specimens. The groups with microcapsules (both phytoncide A- and B-filled) showed significantly lower microhardness and elastic modulus values than the control group (all, P = 0.001). For the trueness, all the RMS values of the whole, upper, and side surfaces of the specimens with microcapsules were less than 100 µm, although significantly higher than those without (all, P = 0.001). The mean flexural strength values of the groups with phytoncide A-filled microcapsule were higher than 65 MPa, not statistically different from that of the control group (all, P > 0.05). However, the groups with phytoncide B-filled microcapsules showed significantly lower values than the control (all, P = 0.001).

CONCLUSIONS

Within the limitations of this in-vitro study, the 3D-printed denture base containing 6 wt% of phytoncide A-filled microcapsules was clinically acceptable in terms of antifungal activity, dimensional accuracy, and flexural strength.

Physical and biological implications of accelerated aging on stereolithographic additive-manufactured zirconia for dental implant abutment

PURPOSE

This study aimed to comparatively investigate the effects of accelerated aging on the physical and biological features of zirconia manufactured by digital light processing (DLP) and conventional subtractive manufacturing (SM) with similar composition.

METHODS

Both the DLP- and SM-fabricated zirconia samples (7 mm × 7.5 mm × 1.5 mm) were grouped according to aging (134 °C, 0.2 MPa, 100% humidity) times, including 0 h, 5 h, and 10 h. Phase assemblage and surface topography of zirconia manufactured by different technologies were evaluated before and after aging. The biological effects of zirconia on human gingival fibroblast (HGF) cell events, including cell viability, proliferation, morphology and adhesion, were also evaluated by live/dead viability assay, cck-8 assay, scanning electron microscopy and confocal laser scanning microscopy respectively.

RESULTS

The DLP-fabricated zirconia showed a higher initial cubic phase content and rate of phase transformation than the SM-fabricated zirconia. Among the different aging time-based groups, the 5 h-aged group exhibited significantly lower sub-micron scale surface roughness compared with the other groups. Aging did not significantly alter cellular behavior in any zirconia type, except for minor changes in adhesive cell numbers recorded in an aging time/culturing time-dependent manner. In addition to small differences in cell alignment patterns and overall cell morphology, the two zirconia types presented comparable biological performance before and after aging.

CONCLUSION

Although the microstructure and surface characteristics of DLP-fabricated zirconia can be affected by autoclave aging, this newly manufactured zirconia is likely to maintain desirable long-term biocompatibility as an implant abutment material.