Comparison of the dimensional and morphological accuracy of three-dimensional digital dental casts digitized using different methods.

The purpose of this study was to compare the accuracy of digital dental casts from plaster cast scanning (PCS), impression scanning (IPS), intraoral scanning (IOS), and cone-beam computed tomography (CBCT) scanning (CCS) methods. The maxillary and mandibular dental casts of 15 patients who needed CBCT scans for oral examination or treatment were digitized via four methods. 12 linear distance measurements of all digital dental casts were selected and acquired with software and compared to those of the reference plaster cast to evaluate the dimensional accuracy. Three-dimensional deviation analysis of the IPS, IOS and CCS groups with respect to the reference PCS group was performed to evaluate the morphological accuracy. The discrepancy in linear distances between the digital dental casts and reference plaster casts was statistically significant (p < 0.01). The dimensional accuracies of the PCS (0.06 ± 0.12 mm) and IPS (0.03 ± 0.05 mm) casts were better than those of the IOS (0.37 ± 0.30 mm) and CCS (0.54 ± 0.40 mm) casts. The one-sample t test showed that there were statistically significant differences between the discrepancies in 8 of the linear distances for the PCS group and 9 of the linear distances for the IPS group between the digital dental casts and reference plaster casts, with an ideal error of 0.00 (p < 0.05). The sequence of morphological accuracy from good to poor was maxillary and mandibular IPS, mandibular IOS; maxillary IOS; and maxillary and mandibular CCS. The accuracy of the digital dental casts from the PCS and IPS methods was greater than that of IOS and CCS methods. Although accuracy of the digital dental cast from IOS was low, it satisfied the clinical requirements for fixed restorations in small units. The accuracy of the digital dental cast from CCS was poorest and could only be used for procedures with lower accuracy requirements.