Comparative analysis of accuracy of SLA and DMLS technologies for cast partial denture frameworks using metrology software

Advanced manufacturing techniques like CAD/CAM and 3D printing have revolutionized dental prosthetics, offering improved precision, efficiency, and accessibility. The accuracy and precision of cast partial dentures significantly affect patient outcomes. To compare the trueness and precision of stereolithography (SLA) and Direct Metal Laser Sintering (DMLS) in fabricating Cast Partial Denture (CPD) frameworks. A partially edentulous mandibular replica was scanned to create a master STL file. Using CAD software, 32 frameworks were designed and produced: 16 using DMLS and 16 using SLA. The frameworks were digitized using a high-precision scanner and compared to the original CAD design using 3D analysis software. Five Areas of Interest (AOIs) were identified: the lingual plate, right and left I-bars, and right and left proximal plates. Gap distances and Root Mean Square (RMS) values were calculated for statistical analysis. No statistically significant differences were found between DMLS and SLA techniques across the five AOIs (p > 0.05). RMS values for DMLS ranged from 0.0290 mm to 0.0348 mm, whereas SLA values ranged from 0.0337 mm to 0.0387 mm. The right proximal plate showed a marginally non-significant difference (p = 0.0560), favoring DMLS. Both DMLS and SLA techniques demonstrated comparable accuracy in producing cast partial denture frameworks across all examined areas. This study provides valuable insights for dental professionals in selecting manufacturing techniques for CPD frameworks by considering factors such as cost and material properties.