International Journal of Prosthodontics and Restorative Dentistry · Published 2026-03-19 · DOI 10.5005/jp-journals-10019-1532
Purpose: To evaluate and compare the dimensional accuracy and stability of dental casts produced using digital light processing (DLP) and stereolithography (SLA) 3D printing technologies over a 3-month period. Materials and methods: 60 maxillary dental casts were 3D printed (<i>n</i> = 30 DLP, <i>n</i> = 30 SLA) from a master STL file. Dimensional accuracy was assessed using root-mean-square (RMS) analysis at baseline, 1 month, and 3 months. Casts were stored in controlled conditions and scanned at each time point. RMS values were calculated using best-fit alignment in metrology software. Statistical analysis was performed using independent <i>t</i>-tests with Shapiro–Wilk test for normality and Welch's correction applied where necessary. Results: SLA casts demonstrated significantly lower RMS values (136.5 ± 12.7 μm) than DLP (153.7 ± 21.9 μm) at baseline (<i>p</i> < 0.001), at 1 month (133.7 ± 14.2 μm and 151.4 ± 17.2 μm, respectively) (<i>p</i> = 0.015). At 3 months, the difference was insignificant (132.8 ± 16.9 μm vs 145.6 ± 29.2 μm, <i>p</i> = 0.826). Both technologies showed a slight decrease in RMS values over time. Color maps revealed more localized deviations in DLP models compared to SLA, with DLP exhibiting primarily minor positive discrepancies on posterior palatal and occlusal surfaces, whereas SLA showed more uniform and neutral or slightly negative deviations. Conclusion: SLA exhibited superior dimensional accuracy compared to DLP, particularly at earlier time points. Both technologies maintained dimensional stability over 3 months under controlled storage. SLA may be more suitable for applications requiring long-term precision, while DLP could suffice for short-term use. Proper storage of models is recommended to maintain dimensional stability.
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