Accuracy evaluation of 3D printed interim prosthesis fabrication using a CBCT scanning based digital model

Objectives: This study aimed to evaluate the marginal and internal gaps in 3D-printed interim crowns made from digital models of cone-beam computed tomography (CBCT) conversion data. Materials and methods: Sixteen polyvinylsiloxane impressions were taken from patients for single crown restorations and were scanned using CBCT. The scanning data were converted to positive Standard Triangulation Language (STL) files using custom-developed software. The fabricated stone models were scanned with an intraoral optical scanner (IOS) to compare the surface accuracy with the STL data obtained by CBCT. The converted STL files were utilized to fabricate interim crowns with a photopolymer using a digital light-processing 3D printer. The replica method was used to analyze the accuracy. The marginal and internal gaps in the replica specimen of each interim crown were measured with a digital microscope. The Friedman test and Mann-Whitney U test (Wilcoxon-signed rank test) were conducted to compare the measurements of the marginal and internal gaps with a 95% level of confidence. Results: The root-mean-square values of the CBCT and IOS ranged from 41.00 to 126.60 μm, and the mean was 60.12 μm. The mean values of the marginal, internal, and total gaps were 132.96 (±139.23) μm, 137.86 (±103.09) μm, and 135.68 (±120.30) μm, respectively. There were no statistically significant differences in the marginal or internal gaps between the mesiodistal and buccolingual surfaces, but the marginal area (132.96 μm) and occlusal area (255.88 μm) had significant mean differences. Conclusion: The marginal gap of the fabricated interim crowns based on CBCT STL data was within the acceptable range of clinical success. Through ongoing developments of high-resolution CBCT and the digital model conversion technique, CBCT might be an alternative method to acquire digital models for interim crown fabrication.