A novel approach for custom three-dimensional printing of a zirconia root analogue implant by digital light processing

Objectives: This study aimed to explore the feasibility of fabrication of three-dimensional (3D)-printed zirconia root analogue implant (RAI) through digital light processing (DLP) technology.
Material and methods: One partially edentulous mandibular human cadaver was scanned with a cone-beam computed tomography (CBCT) system. The scan volumes and data sets were used to create computer-aided design (CAD) model of the RAI. A high-end DLP 3D printing technology was used to fabricate the RAI from the CAD model. Within this approach, solid 3D objects are built using a DLP projector to translate voxel data so it is reproduced in liquid photopolymer dispersed with a commercial ceramic, thereby light polymerizing the resin to solid. Optical scanning technology was used to measure the tooth and 3D-printed RAI. To validate the accuracy of the printed zirconia RAI, the optical surface model of the original tooth and CAD model were superimposed.
Results: The differences between the optical scans of the RAI and original tooth are most noticeable towards the apical foramen, showing a disparity for the RAI with a maximum deviation of 0.86 mm. When setting a maximum threshold of 0.5 mm for the 3D-printed RAI surface to be deviating from the original tooth model and CAD model, measurements show 1.55% and 4.86% of the surface areas are exceeding the threshold distance, respectively. Conclusion: With the use of currently available technology, it is well feasible to 3D print in zirconia a custom RAI.