Assessing the Post-Processing Effect on the Dimensional Accuracy of Additive-Manufactured Surgical Stents.

PURPOSE: To assess the impact of various post-processing techniques on the dimensional accuracy of additive-manufactured dental surgical stents. Dimensional stability is critical for stents used in surgical applications, and understanding the effects of post-processing can inform better manufacturing practices.

METHODOLOGY: An in vitro study was conducted using 30 computer-aided design (CAD)-designed dental stents, printed with a high-resolution resin-based three-dimensional (3D) printer. The stents were divided into three groups (n = 10 per group) for different post-processing treatments: ultraviolet (UV) curing, isopropyl alcohol (IPA) cleaning followed by UV curing, and autoclave sterilization. Dimensional measurements at key points were obtained using a 3D scanner and compared to the CAD model. Statistical analysis determined significant deviations between groups.

RESULTS

The control group showed minimal dimensional deviation. UV curing resulted in a slight increase in deviation (P = 0.04), while IPA + UV curing did not significantly alter accuracy (P = 0.20). Autoclave sterilization showed the most significant deviation (P < 0.05), indicating that high-temperature sterilization compromised dimensional accuracy.

CONCLUSION

UV curing and IPA cleaning maintained close dimensional integrity, making them suitable for applications where both accuracy and material strength are needed. Autoclave sterilization, however, introduced considerable dimensional changes, suggesting the need for alternative sterilization methods for high-precision dental stents.