Evaluating the accuracy of 3D printing of sintered dental metalwork

Additive manufacturing is transforming dentistry, enabling the production of custom metalworks with complex geometries. However, the dimensional accuracy of selective laser sintering remains a critical concern for clinical applications. Here, the accuracy of 3D-printed cobalt-chromium transpalatal arches (TPAs) is assessed by comparing three designs (TPA1, TPA2, TPA3) to their original CAD models. Optical scanning and surface deviation analysis revealed that TPA2 exhibited the highest mean deviation (181 ? 131 ?m), significantly differing from TPA1 (71 ? 78 ?m) and TPA3 (48 ? 26 ?m), which were statistically indistinguishable. These deviations arise from complex design and geometry. Despite this, TPA1 and TPA3 remained within clinically acceptable limits, allowing successful placement without extensive modifications. Our findings highlight the impact of design complexity on manufacturing precision and underscore the need for optimized sintering parameters, build orientation, and post-processing protocols.