Comparison of gap width of thermoformed clear aligners produced by different 3D printers

2025-04-17T07:49:52+00:00

Background: Although clear aligners have been widely used in orthodontics, factors such as thickness and fit are still little studied. In addition, other clinical aspects, such as optical properties, forces and moments and predictability of movement, are fundamental issues for the consolidation of this innovative therapeutic approach. This study aimed to assess how clear aligners manufacturing is impacted by 3D printer techniques and their thermoforming processes through analysis of the model-aligner interface. Methods: Models were printed on three different printers with distinct printing technologies, namely FDM (fused deposition material), SLA (stereolithography apparatus), and DLP (digital light processor). In each case, two resolutions were investigated (i.e. 25 µm and 100 µm). Polyethylene terephthalate glycol (PETG) sheets (Track A, Forestadent^TM, Germany) were made using a thermoforming machine (Plastvac P7, Bio-Art, Brazil) to simulate the orthodontic clear aligner. A universal cutting machine (IsoMet 1000 Precision Cutter, Buehler, UK) was employed to obtain sections of the model-sheet set at the central incisor, canine, first premolar, and first molar regions in the lower arch. The GAP width between models and aligners was obtained through stereomicroscopy (Zeiss, Germany) and measured with Image J/Java software, version 1.46r. Statistical differences were obtained through Analysis of variance (ANOVA) and Tukey’s posthoc test at a significance level of 5%. Results: Gap differences were smaller for SLA and DLP when compared to FDM 3D printer technologies. It was observed that smaller resolutions (100 µm) displayed higher gap widths, relating precision to higher resolutions (25 µm). The assessment of the dental regions did not reveal any distinction relating to resolution or printer techniques. Conclusion: This study showed that SLA and DLP printers produced more precise models than FDM printers used in orthodontics for clear aligners. Factors such as cost, speed and printing capacity may be more important than resolution and GAP for the production of clear aligners in orthodontics.

Keywords: 3D printing; Biomechanics; Clear aligners; Digital orthodontics; Orthodontic appliances.

Synchronous Oral Squamous Cell Carcinoma and Oral Heterotopic Gastrointestinal Cyst: First Case Report

2025-05-26T16:10:35+00:00

Background: Oral squamous cell carcinoma (OSCC) is the most common malignancy of the oral cavity. However, its synchronous occurrence with lesions of a different nature is exceedingly rare, particularly arising at the same anatomical site. Heterotopic gastrointestinal cysts (HGICs) are developmental anomalies containing ectopic gastrointestinal epithelium, typically observed in pediatric patients and rarely reported in adults. Objectives: This report describes an unprecedented case of synchronous OSCC and HGIC of the mouth floor, underscoring the critical role of thorough histopathological evaluation for accurate diagnosis and appropriate management. Description: A 62-year-old man presented with an ulcerated lesion on the right mouth floor. Incisional biopsy followed by histological analysis revealed two distinct lesions: one characterized by a proliferation of atypical squamous cells, consistent with OSCC, and the other by a cystic cavity lined with tall columnar epithelial cells showing basally located nuclei and apical microvilli (brush border), consistent with the diagnosis of HGIC. Definitive treatment included tumor resection and ipsilateral neck dissection. The patient remains under clinical follow-up. Conclusion: To the best of our knowledge, this is the first reported case of synchronous OSCC and HGIC at the same site, highlighting the need for individualized therapeutic planning based on the biological behavior of each lesion.

Keywords

Choristoma; Dentistry; Mouth Neoplasms; Oral Pathology; Squamous Cell Carcinoma of Head and Neck.

Brazilian Dental Science

Comparison of gap width of thermoformed clear aligners produced by different 3D printers

Synchronous Oral Squamous Cell Carcinoma and Oral Heterotopic Gastrointestinal Cyst: First Case Report