Precision-optimized process control in DLP printing of ultra-thin zirconia prostheses: A multi-factor accuracy analysis.

Objectives: This study aims to enhance precision in Digital Light Processing (DLP) 3D printing for ultra-thin zirconia dental prostheses by systematically evaluating key accuracy-influencing factors beyond isolated parameter optimizations.

Methods: Four critical factors, namely, light curing fidelity, support structure stability, asymmetric sintering shrinkage, and whole-process deformation, were analyzed. Parametric optimizations were applied across these stages to improve accuracy, utilizing a 70 μm resolution DLP system to fabricate ultra-thin zirconia veneers (0.1 mm). The difference between the two groups was analyzed using Student's t-test with the level of significance set at 0.05.

Results: The optimized approach achieved an intaglio accuracy of 48 ± 9 μm root mean square (RMS) deviation with 0.1 mm thickness, comparable to milled glass ceramics (47 ± 8 μm) with 0.5 mm thickness. Findings validated the integrated process control framework for minimizing deformation and ensuring precision in zirconia restorations.

Significance: This study provides a validated methodology for scaling DLP-printed zirconia restorations from laboratory prototypes to clinical applications, supporting efficient, precise, and material-conscious prosthetic manufacturing. It not only makes minimally invasive tooth preparation possible, but also enables the production of precise restorations with minimal material waste.