Enhancing dental model accuracy through optimized vat photopolymerization additive manufacturing parameters

• Optimizing vat photopolymerization additive manufacturing process parameters enhances the accuracy of dental models. • Layer thickness, projector power, exposure energy, and vat temperature are key factors in improving accuracy. • The results contribute to better-fitting prosthetics and improved patient outcomes. This study investigates the key additive manufacturing (AM) process parameters that influence the dimensional accuracy of dental models produced using the vat photopolymerization Digital Light Processing (DLP) technology. By applying the Taguchi method, 7AM process factors were analyzed. A standardized post-processing protocol was used to maintain consistency, allowing a focused assessment of the printing parameters. Dimensional deviations were analyzed using 3D scanning and point cloud comparison software, with particular attention to reducing warping and shrinkage. The results identified layer thickness, projector power, exposure energy, and vat temperature as the key AM factors affecting the accuracy of the final model. These findings highlight the importance of optimizing these parameters to achieve high-quality dental models, contributing to future advancements in precision and efficiency. Further research is recommended to determine optimal settings for different resins and more complex dental structures.