Dimensional error of selective laser sintering, three-dimensional printing and PolyJet™ models in the reproduction of mandibular anatomy

SummaryBackgroundSelective laser sintering (SLS), three-dimensional printing (3DP™) and PolyJet™ are rapid prototyping (RP) techniques to fabricate prototypes from virtual biomedical images. To be used in maxillofacial surgery, these models must accurately reproduce the craniofacial skeleton.PurposeTo analyze the capacity of SLS, 3DP™ and PolyJet™ models to reproduce mandibular anatomy and their dimensional error.MaterialDry mandible, helical CT images, SLS, 3DP™ and PolyJet™ prototypes, and digital electronic caliper.MethodsHelical CT images were acquired from a dry mandible (criterion standard) and manipulated with the InVesalius software. Prototypes were produced using SLS, 3DP™ and PolyJet™ techniques. Thirteen linear measurements of each prototype were made and compared with the dry mandible measurements.ResultsThe results showed a dimensional error of 1.79%, 3.14% and 2.14% for SLS, 3DP™ and PolyJet™ models, respectively. The models satisfactorily reproduced anatomic details and the SLS and PolyJet™ prototypes showed greater dimensional precision and reproduced mandibular anatomy more accurately than the 3DP™ model.ConclusionsThe SLS prototype had a greater dimensional accuracy than the PolyJet™ and 3DP™ models. The PolyJet™ technique reproduced anatomic details of the mandible more accurately.