Accuracy of casts produced from conventional and digital workflows: A qualitative and quantitative analyses

PURPOSE: Comparing the accuracy of casts produced from digital workflow to that of casts produced from conventional techniques. MATERIALS AND METHODS: Whole arch alginate (ALG) and polyvinyl siloxane (PVS) impressions were taken with stock trays and custom trays, respectively. The ALG impressions were poured with type III dental stone, while the PVS impressions were poured with type IV dental stone. For the digital workflow, IOS impressions were taken and physical casts were produced by 3D printing. In addition, 3D printed casts were produced from images obtained from a laboratory scanner (LS). For each technique, a total of 10 casts were produced. The accuracies of the whole arch and separated teeth were virtually quantified. RESULTS: Whole arch cast accuracy was more superior for PVS followed by LS, ALG, and IOS. The PVS and ALG groups were inferior in the areas more susceptible to impression material distortion, such as fossae and undercut regions. The LS casts appeared to have generalized errors of minor magnitude influencing primarily the posterior teeth. The IOS casts were considerably more affected at the posterior region. On the contrary, the IOS and LS casts were more superior for single tooth accuracy followed by PVS and ALG. CONCLUSION: For whole arch accuracy, casts produced from IOS were inferior to those produced from PVS and ALG. The inferior outcome of IOS appears to be related to the span of scanning. For single tooth accuracy, IOS showed superior accuracy compared to conventional impressions.