Effects of printing layer thickness and build orientation on the mechanical properties and color stability of 3D-printed clear aligners.

Objectives: To determine effects of printing layer thickness and build orientation on mechanical properties and color stability of direct 3D-printed clear aligner resin.

Materials and methods: Specimens were printed using 3D printed clear aligner resin with two printing layer thicknesses (50 µm, 100 µm) and three build orientations (90°, 60°, and 45°). Mechanical properties (tensile stress, tensile strain, and elastic modulus), color stability in coffee and artificial saliva, and roughness were then evaluated.

Results: Specimens printed with a 50 µm layer thickness and orientation at 90° demonstrated superior color stability in artificial saliva. However, all specimens showed high susceptibility to coffee staining regardless of layer thickness or orientation. Mechanical properties were improved in the order of 90° < 60° < 45° build orientation, showing statistically significant differences (P < .05). Surface roughness was increased in the order of 90° < 60° < 45° build orientation, showing statistically significant differences (P < .05).

Conclusions: Printing layer thickness and orientation exerted significant effects on mechanical properties, color stability, and surface roughness of 3D-printed clear aligner resin.