Effect of the Height of a 3D-Printed Model on the Force Transmission and Thickness of Thermoformed Orthodontic Aligners.

This research aims to investigate the influence of model height employed in the deep drawing of orthodontic aligner sheets on force transmission and aligner thickness. Forty aligner sheets (Zendura FLX) were thermoformed over four models of varying heights (15, 20, 25, and 30 mm). Normal contact force generated on the facial surface of the upper right central incisor (Tooth 11) was measured using pressure-sensitive films. Aligner thickness around Tooth 11 was measured at five points. A digital caliper and a micro-computed tomography (µ-CT) were employed for thickness measurements. The normal contact force exhibited an uneven distribution across the facial surface of Tooth 11. Model 15 displayed the highest force (88.9 ± 23.2 N), while Model 30 exhibited the lowest (45.7 ± 15.8 N). The force distribution was more favorable for bodily movement with Model 15. Thickness measurements revealed substantial thinning of the aligner after thermoforming. This thinning was most pronounced at the incisal edge (50% of the original thickness) and least at the gingivo-facial part (85%). Additionally, there was a progressive reduction in aligner thickness with increasing model height, which was most significant on the facial tooth surfaces. We conclude that the thermoplastic aligner sheets undergo substantial thinning during the thermoforming process, which becomes more pronounced as the height of the model increases. As a result, there is a decrease in both overall and localized force transmission, which could lead to increased tipping by the aligner and a diminished ability to achieve bodily movement.

Trueness and precision of digital light processing fabricated 3D printed monolithic zirconia crowns.

OBJECTIVES: The present study aimed to evaluate the trueness and precision of monolithic zirconia crowns (MZCs) fabricated by 3D printing and milling techniques. METHODS: A premolar crown was designed after scanning a prepared typodont. Twenty MZCs were fabricated using milling and 3D-printing techniques (n = 10). All the specimens were scanned with an industrial scanner, and the scanned data were analyzed using 3D measurement software to evaluate the trueness and precision of each group. Root mean square (RMS) deviations were measured and statistically analyzed (One-way ANOVA, Tukey's, p ≤ 0.05). RESULTS: The trueness of the printed MZC group (140 ± 14 µm) showed a significantly higher RMS value compared to the milled MZCs (96 ± 27 µm,p < 0.001). At the same time, the precision of the milled MZCs (61 ± 17 µm) showed a significantly higher RMS value compared to that of the printed MZCs (31 ± 5 µm,p < 0.001). CONCLUSIONS: The Fabrication techniques had a significant impact on the accuracy of the MZCs. Milled MZCs showed the highest trueness, while printed MZCs showed the highest precision. All the results were within the clinically acceptable error values. CLINICAL SIGNIFICANCE: Although the trueness of the milled MZCs is higher, the manufacturing accuracy of the 3D-printed MZCs showed clinically acceptable results in terms of trueness and precision. However, additional clinical studies are recommended. Furthermore, the volumetric changes of the material should be considered.

Effect of material composition and thickness of orthodontic aligners on the transmission and distribution of forces: an in vitro study.

OBJECTIVES: To investigate the effects of material type and thickness on force generation and distribution by aligners. MATERIALS AND METHODS: Sixty aligners were divided into six groups (n = 10): one group with a thickness of 0.89 mm using Zendura Viva (Multi-layer), four groups with a thickness of 0.75 mm using Zendura FLX (Multi-layer), CA Pro (Multi-layer), Zendura (Single-layer), and Duran (Single-layer) sheets, and one group with a thickness of 0.50 mm using Duran sheets. Force measurements were conducted using Fuji® pressure-sensitive films. RESULTS: The lowest force values, both active and passive, were recorded for the multi-layered sheets: CA Pro (83.1 N, 50.5 N), Zendura FLX (88.9 N, 60.7 N), and Zendura Viva (92.5 N, 68.5 N). Conversely, the highest values were recorded for the single-layered sheets: Duran (131.9 N, 71.8 N) and Zendura (149.7 N, 89.8 N). The highest force was recorded at the middle third of the aligner, followed by the incisal third, and then the cervical third. The net force between the incisal and cervical thirds (FI-FC) showed insignificant difference across different materials. However, when comparing the incisal and middle thirds, the net force (FI-FM) was higher with single-layered materials. Both overall force and net force (FI-FM) were significantly higher with 0.75 mm compared to those with a thickness of 0.50 mm. CONCLUSIONS: Multi-layered aligner materials exert lower forces compared to their single-layered counterparts. Additionally, increased thickness in aligners results in enhanced retention and greater force generation. For effective bodily tooth movement, thicker and single-layered rigid materials are preferred. CLINICAL RELEVANCE: This research provides valuable insights into the biomechanics of orthodontic aligners, which could have significant clinical implications for orthodontists. Orthodontists might use this information to more effectively tailor aligner treatments, considering the specific tooth movement required for each individual patient. In light of these findings, an exchangeable protocol for aligner treatment is suggested, which however needs to be proven clinically. This protocol proposes alternating between multi-layered and single-layered materials within the same treatment phase. This strategy is suggested to optimize treatment outcomes, particularly when planning for a bodily tooth movement.

Effect of attachment configuration and trim line design on the force system of orthodontic aligners: A finite element study on the upper central incisor.

OBJECTIVES: To use the finite element method (FEM) to investigate the effect of various attachment configurations and trimming line designs of orthodontic aligners on their biomechanical performance. METHOD: A 3D upper jaw model was imported into 3D design software. The upper right central incisor tooth (Tooth 11) was made mobile, and its periodontal ligament (PDL) and bone structures were designed. Aligners were modelled with three distinct attachment configurations: No attachment, rectangular horizontal, rectangular vertical, and two trimming line designs; scalloped and straight extended, with a homogeneous thickness of 0.6 mm. These models were then imported into an FE software. Simulations were conducted for three different movements, including facial translation, distalization, and extrusion. RESULTS: Forces were recorded at 1.3-2.6 N during facial translation, 1.4-5.9 N in distalization, and 0.0-2.0 N in extrusion. The straight extended trimming line consistently generated higher forces than the scalloped design. Attachments had no significant impact on force components during facial translation but were more effective in distalization and extrusion. The combination of a straight extended trimming line with horizontal attachments exhibited the least stresses at the apical third during distalization, and the highest stresses during extrusion, suggesting superior retention. CONCLUSIONS: Rectangular attachments offer limited benefits in facial translation, but horizontal rectangular attachments can intensify load in distalization and are crucial for force generation in extrusion. Horizontal attachments are preferred over vertical options. Additionally, the straight extended trim line enhances control of tooth movement and can replace attachments in certain cases. CLINICAL RELEVANCE: These findings provide biomechanical evidence and an optimal protocol to guide clinical practice in planning diverse teeth movements. The emphasis is on the influence of attachment utilization and the specific design of aligner trimming lines to enhance control over tooth movement.

Evaluation of micromotion in multirooted root analogue implants embedded in synthetic bone blocks: an in vitro study.

BACKGROUND: While conventional threaded implants (TI) have proven to be effective for replacing missing teeth, they have certain limitations in terms of diameter, length, and emergence profile when compared to customised root analogue implants (RAI). To further investigate the potential benefits of RAIs, the aim of this study was to experimentally evaluate the micromotion of RAIs compared to TIs. METHODS: A 3D model of tooth 47 (mandibular right second molar) was segmented from an existing cone beam computed tomography (CBCT), and a RAI was designed based on this model. Four RAI subgroups were fabricated as follows: 3D-printed titanium (PT), 3D-printed zirconia (PZ), milled titanium (MT), milled zirconia (MZ), each with a sample size of n = 5. Additionally, two TI subgroups (B11 and C11) were used as control, each with a sample size of n = 5. All samples were embedded in polyurethane foam artificial bone blocks and subjected to load application using a self-developed biomechanical Hexapod Measurement System. Micromotion was quantified by analysing the load/displacement curves. RESULTS: There were no statistically significant differences in displacement in Z-axis (the loading direction) between the RAI group and the TI group. However, within the RAI subgroups, PZ exhibited significantly higher displacement values compared to the other subgroups (p < 0.05). In terms of the overall total displacement, the RAI group showed a statistically significant higher displacement than the TI group, with mean displacement values of 96.5 µm and 55.8 µm for the RAI and TI groups, respectively. CONCLUSIONS: The RAI demonstrated promising biomechanical behaviour, with micromotion values falling within the physiological limits. However, their performance is less predictable due to varying anatomical designs.

Trueness and precision of milled and 3D printed root-analogue implants: A comparative in vitro study.

OBJECTIVES: The present study aimed to evaluate the accuracy (trueness and precision) of titanium and zirconia multi-rooted root analogue implants (RAIs) manufactured by milling and 3D-printing. METHODS: A multi-rooted RAI was designed based on a mandibular second molar segmented from cone-beam computed tomography (CBCT). The manufactured RAIs were divided into four groups: 3D-printed titanium (PT) and 3D-printed zirconia (PZ) (n=10 each), as well as milled titanium (MT) and milled zirconia (MZ) (n=5 each). The specimens were scanned with a high-precision scanner, and the scanned data were imported into 3D-measurement software to evaluate the precision and trueness of each group. Root mean square (RMS) deviations were measured and statistically analysed (One-way ANOVA, Tukey's, p≤0.05). RESULTS: PZ showed the highest precision with RMS value of 21±6 µm. Nevertheless, there was no statistically significant difference in precision among the other groups. Regarding trueness, MZ showed the highest trueness with RMS value of 66±3 µm, whereas MT showed the lowest trueness result. Inspection sections showed that MT had significantly high RMS deviation in the furcation area (612±64 µm), whereas PZ showed significantly high RMS deviation at the apical area (197±17 µm). CONCLUSIONS: The manufacturing process significantly influenced the RAI accuracy. PZ exhibited the highest precision, whereas MZ exhibited the highest trueness, followed by PT. Finally, our results suggest that 3D-printing can reproduce concave surfaces and less accessible areas better than milling. CLINICAL SIGNIFICANCE: Milled and 3D-printed RAIs showed promising results in terms of precision and trueness. However, further clinical research is needed to advocate their use as immediate implants. Additionally, the inherent volumetric changes of the various materials during manufacturing should be considered.

Computer-aided finite element model for biomechanical analysis of orthodontic aligners.

OBJECTIVES: To design a finite element (FE) model that might facilitate understanding of the complex mechanical behavior of orthodontic aligners. The designed model was validated by comparing the generated forces - during 0.2-mm facio-lingual translation of upper left central incisor (Tooth 21) - with the values reported by experimental studies in literature. MATERIALS AND METHODS: A 3D digital model, obtained from scanning of a typodont of upper jaw, was imported into 3-matic software for designing of aligners with different thicknesses: 0.4, 0.5, 0.6, 0.7 mm. The model was exported to Marc/Mentat FE software. Suitable parameters for FE simulation were selected after a series of sensitivity analyses. Different element classes of the model and different rigidity values of the aligner were also investigated. RESULTS: The resultant maximum forces generated on facio-lingual translation of Tooth 21 were within the range of 1.3-18.3 N. The force was direction-dependent, where lingual translation transmitted higher forces than facial translation. The force increases with increasing the thickness of the aligner, but not linearly. We found that the generated forces were almost directly proportional to the rigidity of the aligner. The contact normal stress map showed an uneven but almost repeatable distribution of stresses all over the facial surface and concentration of stresses at specific points. CONCLUSIONS: A validated FE model could reveal a lot about mechanical behavior of orthodontic aligners. CLINICAL RELEVANCE: Understanding the force systems of clear aligner by means of FE will facilitate better treatment planning and getting optimal outcomes.

Effect of trimming line design and edge extension of orthodontic aligners on force transmission: An in vitro study.

OBJECTIVES: To investigate how the stress distribution and forces transmitted from orthodontic aligners to the tooth surface are affected by the geometry and extension of the trimming line. MATERIALS AND METHODS: Thirty-six aligners were thermoformed from Zendura FLX sheets (0.75 mm thick) and divided into four groups based on the design of the trimming line: Scalloped, Scalloped extended, Straight and Straight extended. Fuji pressure-sensitive films were used for pressure measurement. The pressurized films were scanned and evaluated. Pressures and forces were measured over the entire facial surface of an upper right central incisor (Tooth 11) and at 7 different locations [cervical, middle, incisal, mesio-incisal, mesio-cervical, disto-incisal, and disto-cervical]. In addition, the thickness of the aligners at these 7 sites was measured with a digital caliper. RESULTS: The active force ranged from (2.2 to 6.9) N, and the average pressure was (1.6-2.7) MPa. The highest values were recorded for the (straight extended) design, while the lowest values were recorded for the scalloped design. The forces and stresses were not uniformly distributed over the surface. When the values in each area were compared separately, significant differences were found between the different designs in the cervical area, with the scalloped design transmitting the lowest cervical forces. Aligner thickness was drastically reduced (60-75% thinning) over the entire tooth surface after thermoforming. CONCLUSIONS: The straight extended design of aligner's trimming line exhibited more uniform force transfer and stress distribution across the surface than the other designs. CLINICAL RELEVANCE: The trimming line design could have a significant impact on the clinical outcome of orthodontic aligner treatment.

Biomechanical behavior of endodontically treated premolars restored with different endocrown designs: Finite element study.

PURPOSE: Although endocrown is a successful restorative approach for endodontically treated molars, its survival rate in endodontically treated premolars with extensive loss of coronal structure has been debated. The aim of this study was to evaluate the biomechanical behavior of endodontically treated maxillary premolars restored with different lithium disilicate endocrown designs. MATERIALS AND METHODS: Based on cone-beam computed tomography (CBCT) of an intact maxillary premolar, five models were designed. Model A: fiber post, core, and crown; Model B: endocrown, 5 mm pulpal extension and butt margin; Model C: endocrown, 5 mm pulpal extension and axial extension; Model D: Endocrown, 3 mm pulpal extension and butt margin; Model E: Endocrown, 3 mm pulpal extension and axial extension. The bone geometry was simplified as a cylinder of compact and trabecular bone. All models were imported into finite element analysis (FEA) software, where the base of the bone cylinder was chosen as fixed support. Axial and oblique loads of 100 N each were applied separately to each model, and static structural analysis was performed. RESULTS: Regardless of the design of the endocrown, the resulting von Mises stresses were far below the yield strength of the tooth structure and the flexural strength of the ceramic material. The generated von Mises stresses on the restoration decreased by 15% in the models with 3 mm pulp extension (D and E) compared to the 5-mm pulpal extension models. In addition, the resulting von Mises stresses on the tooth structure decreased also by 15% in models C and E with the axial extension compared to models B and D with the butt margin. CONCLUSION: Endocrown is a suitable restoration for endodontically treated maxillary premolars. Furthermore, reducing the depth of the pulpal extension to 3 mm with the addition of an axial extension resulted in a more favorable stress distribution within the tooth-restoration interface.