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Dimensional accuracy of mock-ups fabricated using conventional, additive, and subtractive manufacturing techniques: an in vitro study

Year: 2026
Type: preprint
Abstract: Background Mock-ups are used to preview esthetic and functional outcomes and may also guide minimally invasive tooth preparation. This in vitro study compared the dimensional accuracy of six-unit anterior mock-ups fabricated using conventional molding, additive manufacturing, and subtractive manufacturing relative to a reference digital design. Methods Digital smile design data from 10 patients were used to fabricate one canine-to-canine mock-up per patient with each manufacturing technique (n = 10 per technique; 30 specimens). Conventional mock-ups were produced using a silicone index and bis-acryl resin, additive mock-ups were fabricated with a liquid crystal display-based three-dimensional printer, and subtractive mock-ups were milled from prepolymerized polymethyl methacrylate discs. Specimens were digitized with an industrial optical scanner and superimposed on the reference digital waxing. Surface-to-surface matching percentages, absolute digital and analog linear deviations, and signed depth deviations at nine standardized points per tooth were assessed. Data were analyzed using one-way analysis of variance and Kruskal-Wallis tests with appropriate post-hoc comparisons (α = 0.05). Results Surface-to-surface matching differed significantly among the techniques (p = 0.001). The subtractive group showed the highest matching percentage (74.54 ± 12.26%), followed by the additive (58.72 ± 18.84%) and conventional (42.80 ± 12.46%) groups; the subtractive group differed significantly from the conventional group (p = 0.001), whereas the other pairwise comparisons were not significant. No significant differences were observed in digital or analog absolute linear deviations (p > 0.05). The conventional group showed significantly lower signed depth deviation values than the subtractive (p = 0.001) and additive (p = 0.021) groups. Depth deviations differed by tooth type, with the highest values in canines and the lowest in central incisors (p = 0.001), but not by mesio-distal region (p = 0.453). Conclusions Manufacturing technique influenced the three-dimensional accuracy of anterior mock-ups, although selected linear dimensions were reproduced similarly. Subtractive manufacturing showed the highest surface matching, while additive manufacturing showed intermediate matching and mean depth deviations close to zero. Region-specific deviations observed with conventional molding should be considered when mock-ups are used as preparation guides.
DOI: 10.21203/rs.3.rs-10549482/v1
Institution: Trakya University
Language: English
Field: Dentistry
Open Access status: green
OpenAlex ID: W7204453956
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