Effect of simulated bur radius compensation on full-contour CAD crown morphology and trueness across tooth types. An in- silico study

at the maximum radius. Conversely, surface area and roughness metrics showed a consistent upward trend. Geometric trueness deteriorated substantially with larger radii. While maximum localized deviations (H.D) peaked between the 0.75 mm and 1.00 mm settings, overall morphological deviation (RMSE) continued to climb, peaking at the 1.25 mm to 1.50 mm settings depending on the tooth type. Specifically, the RMSE for the central incisor rose from 0.049 at the minimal compensation to a peak of 0.184, indicating substantial volumetric and geometric distortion compared to the ideal baseline design. The selection of bur radius size directly dictates the morphological reliability of dental CAD. The data demonstrate that a minimal radius (0.10 mm) yields the highest trueness to the ideal baseline, whereas larger settings cause substantial volumetric reduction and geometric deviation, particularly in posterior teeth. To minimize anatomical discrepancies, digital laboratory workflows better to restrict bur radius compensation to the minimum technically feasible values, pending further validation in physical milling processes.