Build angle effect on 3D-printed dental crowns marginal fit using digital light-processing and stereo-lithography technology: an in vitro study.

BACKGROUND: The effect of 3D printing technology and build angle on the marginal fit of printed crowns is unclear. The objective of this research was to use digital light processing (DLP) and stereo-lithography (SLA)-based 3D printing to construct single restorations with varied build angles and to analyze the crowns' marginal fit. METHODS: A prepared resin first molar was scanned utilizing an optical scanner. Three build orientations were used to construct the specimens: 0, 45, and 90º. DLP and SLA technology were used to produce the casting patterns. A digital microscope was used to measure the marginal gaps. The effect of build orientation was statistically analyzed by using Two-way ANOVA followed by pair-wise Tukey test. RESULTS: Two-way ANOVA revealed a significant effect of printer technology and build angle on the marginal discrepancy of 3D printed crowns (p < 0.001). One-way ANOVA revealed that SLA printers (55.6 [± 13.59]) showed significantly better mean [± SD] marginal discrepancy in µm than DLP printers (72 [± 13.67]) (p < 0.001). Regarding build angle, one-way ANOVA revealed significant differences between the different angles. Tukeys post-hoc test revealed that 0° (48.5 [± 9.04]) had the significantly smallest marginal discrepancy followed by 45° (62.5 [± 8.05]) then 90° (80.5 [± 8.99]) (p < 0.001). CONCLUSION: The build orientation affects the marginal discrepancy of single crowns manufactured utilizing DLP and SLA.

Structural tuning of anisotropic mechanical properties in 3D-Printed hydrogel lattices.

We investigated the ability to tune the anisotropic mechanical properties of 3D-printed hydrogel lattices by modifying their geometry (lattice strut diameter, unit cell size, and unit cell scaling factor). Many soft tissues are anisotropic and the ability to mimic natural anisotropy would be valuable for developing tissue-surrogate "phantoms" for elasticity imaging (shear wave elastography or magnetic resonance elastography). Vintile lattices were 3D-printed in polyethylene glycol di-acrylate (PEGDA) using digital light projection printing. Two mechanical benchtop tests, dynamic shear testing and unconfined compression, were used to measure the apparent shear storage moduli (G') and apparent Young's moduli (E) of lattice samples. Increasing the unit cell size from 1.25 mm to 2.00 mm reduced the Young's and shear moduli of the lattices by 91% and 85%, respectively. Decreasing the strut diameter from 300 µm to 200 µm reduced the apparent shear moduli of the lattices by 95%. Increasing the geometric scaling ratio of the lattice unit cells from 1.00 × to 2.00 × increased mechanical anisotropy in shear (by a factor of 3.1) and in compression (by a factor of 2.9). Both simulations and experiments show that the effects of unit cell size and strut diameter are consistent with power law relationships between volume fraction and apparent elastic moduli. In particular, experimental measurements of apparent Young's moduli agree well with predictions of the theoretical Gibson-Ashby model. Thus, the anisotropic mechanical properties of a lattice can be tuned by the unit cell size, the strut diameter, and scaling factors. This approach will be valuable in designing tissue-mimicking hydrogel lattice-based composite materials for elastography phantoms and tissue engineered scaffolds.

DLP fabrication of HA scaffold with customized porous structures to regulate immune microenvironment and macrophage polarization for enhancing bone regeneration.

The immune microenvironment plays a pivotal role in osteoanagenesis. Biomaterials can modulate osteogenic efficacy by inducing specific local immune reactions. As 3D-printing technology advances, digital light projection printing has emerged as a promising method for creating large scale, high-precision biomaterial scaffolds. By adjusting the solid content and the sintering conditions during printing, the pore size of biomaterials can be meticulously controlled. Yet, the systematic influence of pore size on the immune microenvironment remains uncharted. We fabricated 3D-printed hydroxyapatite bioceramic scaffolds with three distinct pore sizes: 400 µm, 600 µm, and 800 µm. Our study revealed that scaffolds with a pore size of 600 µm promote macrophage M2 polarization, which is achieved by upregulating interferon-beta and HIF-1α production. When these materials were implanted subcutaneously in rats and within rabbit skulls, we observed that the 600 µm scaffolds notably improved the long-term inflammatory response, fostered vascular proliferation, and augmented new bone growth. This research paves the way for innovative therapeutic strategies for treating large segmental bone defects in clinical settings.

Recent developments in digital light processing 3D-printing techniques for microfluidic analytical devices.

Digital light processing (DLP) 3D printing is rapidly advancing and has emerged as a powerful additive manufacturing approach to fabricate analytical microdevices. DLP 3D-printing utilizes a digital micromirror device to direct the projected light and photopolymerize a liquid resin, in a layer-by-layer approach. Advances in vat and lift design, projector technology, and resin composition, allow accurate fabrication of microchannel structures as small as 18 × 20 µm. This review describes the latest advances in DLP 3D-printing technology with respect to instrument set-up and resin formulation and highlights key efforts to fabricate microdevices targeting emerging (bio-)analytical chemistry applications, including colorimetric assays, extraction, and separation.

Effects of build orientation and bar addition on accuracy of complete denture base fabricated with digital light projection: An in vitro study.

PURPOSE: We evaluated the effects of build orientation and bar addition between lingual flanges on the accuracy of mandibular denture bases fabricated using a digital light processing (DLP) device. METHODS: Mandibular denture bases with and without a bar at the lingual flanges were virtually designed and assigned to eight build orientations. Six dentures per condition were fabricated using a DLP device with a methacrylate-based photopolymerizable monomer (Dima Print denture base) (n=96). The fabricated denture surfaces were digitized, and intaglio surfaces were obtained. These digitized surfaces were compared via superimposition using graphical software (Artec studio12 profession) to their original designed files, and root mean square estimates were obtained. The trueness of the entire and intaglio data was statistically analyzed non-parametrically. RESULTS: The range of trueness of the entire and intaglio denture bases was 0.15-0.31 mm and 0.11-0.38 mm, respectively. The trueness at 135° and 270° for the entire denture base and that at 270° for the intaglio data without the bar were significantly lower than those for the other build orientations. The trueness at 270° was <0.15 mm irrespective of the conditions. The trueness with the bar of all build orientations, except that of 0° for intaglio data, was significantly smaller than or equal to the trueness without the bar of the corresponding build orientations. CONCLUSIONS: Build orientation and bar addition influenced the accuracy of the complete dentures fabricated using DLP. A build orientation of 270° is recommended for fabricating a mandibular complete denture, irrespective of the bar addition.

Additive manufacturing of lithium disilicate glass-ceramic by vat polymerization for dental appliances.

OBJECTIVES: The objectives of this study were to evaluate the mechanical properties of lithium disilicate components produced by additive manufacturing (AM) and to assess the effect of build orientation on the resistance to fracture. METHODS: Oversized bars were printed with a glass-filled photoactive resin using a digital light processing technique. After sintering and post-processing, flexure and chevron notch fracture toughness bars were obtained in three principal orientations (0°, 45°, and 90°) with respect to the build direction. Mechanical properties were obtained according to the relevant ASTM standards. The hardness, indentation fracture resistance, and elastic modulus were measured for each orientation, and a Weibull analysis was conducted with the flexure responses. Fractography of the fracture surfaces was performed to identify the failure origins. RESULTS: The 0° orientation exhibited characteristic strength, Weibull modulus, and elastic modulus of 313 MPa, 4.42, and 168 ± 3 GPa, respectively, which are comparable to lithium disilicate materials from traditional processes. However, build orientation contributed significantly to the flexure strength, elastic modulus, and Weibull modulus; the characteristic strengths for the 45° and 90° build orientations were 86 MPa and 177 MPa, respectively. The primary contribution to the orientation dependence was the number of residual build layer-related flaws from incomplete union between printed layers. Of note, hardness and the fracture toughness were not dependent on build orientation. SIGNIFICANCE: AM of lithium disilicate materials can achieve the mechanical properties of materials produced by traditionally processing. Thus, while further process development is warranted, the outlook for dentistry is promising.

Modeling the printability of photocuring and strength adjustable hydrogel bioink during projection-based 3D bioprinting.

As a projection based three-dimensional printing method, digital light processing bioprinting (DLPBP) has higher printing resolution and is suitable for constructing finer structures to mimic tissues when compared to extrusion based bioprinting. However, there is a lack of understanding about printing behavior during DLPBP. Herein, a photo crosslinking theory for ink was established and a specified amount of light absorber was added to control crosslinking depth. Then, a standardized methodology was established to quantitatively evaluate printing resolution using different parameters. Complex biostructures, such as the ear, hand, and heart, were precisely printed after understanding the mechanism. Additionally, the mechanical properties of printed samples were accurately adjusted by changing the hydrogel concentration, as well as the degree of substitution and photocrosslinking time. The tissue types printed were from ultra-soft tissues, such as liver (6-8 kPa) to soft tissue, such as the skin (0.3-0.4 MPa). A branching vessel with cells in a real tensile modulus was printed as a demonstration. After 1 week of culture, proliferation and function of human umbilical vein endothelial cells were characterized. Overall, we made it possible to print a mimic complex tissue with high precision, required physical properties and functionalized living cells.

Effects of build conditions and angle acuteness on edge reproducibility of casting patterns fabricated using digital light projection.

The aim of the present study was to evaluate the effects of build conditions and angle acuteness on edge reproducibility of the casting patterns fabricated using a digital light process. The prism-shaped patterns with various vertex angles were fabricated in three build orientations. The height from the base to the vertex angle point of the fabricated pattern was measured and the incomplete height was calculated as the discrepancy between the original and measured heights. Two-way ANOVA revealed that the vertex angle and build orientation and their interaction were significant (p<0.05). The incomplete height significantly decreased with an increase of the vertex angle. When the vertex angle was 20° and the build-up direction was parallel to the edge of vertex angle and perpendicular to the triangular base, the incomplete height was the smallest. Therefore, build orientation and angle acuteness influenced the edge reproducibility of the casting patterns fabricated using a digital light process.

Vat Polymerization-Printed Partially Stabilized Zirconia: Mechanical Properties, Reliability and Structural defects.

Additive manufacturing (AM) of ceramics, particularly of zirconia, is becoming of increasing interest due to the substantial freedom available in the design and fabrication process. However, due to the novelty of the field and the challenges associated with printing dense bulk ceramics suitable for structural applications, thorough investigations that explore the effects of printing on the mechanical performance are limited. Previous work has identified anisotropy in the mechanical properties and attributed it to the layer-by-layer deposition. However, substantiated fractographic evidence detailing the origins and effects of layer lines on the probability of failure are limited. This study investigates the mechanical properties of a dense (>99 %TD), partially stabilized zirconia fabricated by a digital light projection printing method following ASTM standards. Hardness and strength evaluations were conducted, followed by a Weibull analysis and fractography. The investigation entailed five unique build directions and a conventionally manufactured reference material that was used as a control. Although the strengths were comparable to the reference material for some orientations, fracture frequently initiated at layer lines and related defects in all orientations. The findings indicate that if the layer lines can be prevented or engineered, the strength of vat printed ceramics can be improved substantially.