Dimensional accuracy of clear aligners fabricated using different LCD 3D printer resolutions: an in-vitro study

PurposeThe aim of this study is to compare trueness and precision of dental models from three LCD 3D printers with different horizontal resolutions (2K, 4K, 8K) and to evaluate their clinical suitability for orthodontic use.Materials and MethodsThirty models were printed using Creality Halot One (2K), Phrozen Mighty 4K, and Phrozen Mighty 8K printers, with ten models each using manufacturer-recommended resins. Master digital models from intraoral scans were compared to re-scanned printed models through surface superimposition using Geomagic Control X software. Trueness and precision were evaluated by point deviation and Root-Mean-Square (RMS) analysis, with differences assessed by one-way ANOVA (p = 0.05).ResultsMean RMS values for 2K, 4K, and 8K printers were 0.266 ± 0.015 mm, 0.223 ± 0.017 mm, and 0.121 ± 0.012 mm, respectively (p < 0.001). The 8K printer showed highest trueness and precision, with deviations mainly in occlusal and gingival regions. The 0.25 mm error limit was within acceptable range for 4K and 8K models, while 2K models exceeded this value (p < 0.05).ConclusionPrinter resolution significantly affects dimensional accuracy. The 8K LCD printer demonstrated superior accuracy and reproducibility, proving reliable for orthodontic models and clear aligners.