Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
in dentistry: a review
Abbas Azari and Sakineh Nikzad
Faculty of Dentistry, Department of Removable Prosthodontics, Tehran University of Medical Sciences, Tehran, Iran
Abstract
Purpose The goal of rapid mechanical prototyping is to be able to quickly fabricate complex-shaped, 3D parts directly from computer-aided design
models. The key idea of this novel technology is based upon decomposition of 3D computer models data into thin cross-sectional layers, followed by
physically forming the layers and stacking them up; layer by layer technique. This new method of modeling has raised many attentions in dentistry
especially in the field of surgery and implantology. The purpose of this review study is to represent the historical development and various methods
currently used for building dental appliances. It is also aimed to show the many benefits which can be achieved by using this new technology in various
branches of dentistry.
Design/methodology/approach The major existing resources, including unpublished data on the internet, were considered.
Findings Although, creating 3D objects in a layered fashion is an idea almost as old as human civilization but, this technology has only
recently been employed to build 3D complex models in dentistry. It seems that in near future many other methods will develop which could
change traditional dental practices. It is advisable to include more unit hours in dental curriculums to acquaint dental students with the many
benefits of this novel technology.
Originality/value It is hard to believe that the routine dental techniques were affected by revolutionary concepts originally theorized by engineering
methods. It is a reality that in future, most of the restorative disciplines will be fully revised and the computer methods be evolved to an extent where
dentistry can be performed by computer-assisted methods with optimum safety, simplicity, and reliability.
The concept of modeling; dental approach mechanics, electronics, metallurgy, and many others. In view
of this fact, several merging technologies have been evolved by
Model and modeling are common terms amongst dental utilizing both techniques in a wise manner. This
professionals. Perhaps, from the inception of modern multidisciplinary approach drastically improved sciences like
dentistry, these terms have been used in many different prosthodontics and restorative dentistry in many aspects.
forms and for various necessities. According to the Glossary Although merging different technologies were initially very
of prosthodontic terms (The Academy of Prosthodontics, beneficial but, soon after some conflict arose from
2005) (GPT 8), The term model has been used in dentistry interdisciplinary terms and this has affected dentistry. The
since 1572 and defined as a miniature representation of term model is one of these interdisciplinary terms which are
something; an example for imitation or emulation. not defined with similarity.
Surprisingly, this term however, is not defined in medicine Usually, models used in dentistry are made by impression
in the same manner. In Merriam-Websters Medical Desk making techniques in which some type of specially designed
Dictionary (model definition, 2008), the term model is defined liquefy materials set in the mouth after a specific period of
as to produce (as by computer) a representation or time. These materials, namely impression materials,
simulation of. One may be confused with this non- commonly transfer to patients mouth by means of a holder
similarity in definition but, it is obvious that emulation device called tray. It is generally perceived among dental
and simulation are not the same. The spreading of professions that an impression, or negative likeness of the
engineering sciences in the medical/dental counterpart, teeth and surrounding structures, is necessary to obtain a cast
made it possible to gain access to these two different which can then be used to make a restoration in the
disciplines and find good explanations and solutions for laboratory. For more than a century, this technology was
problems routinely involved in each methodology. It is a taught in dental faculties as a relatively cheap and easy to use
reality that dentistry, in its modern form, has been affected by technique. This technology however necessitates skillful
the techniques utilized in other science methodologies such as human efforts, i.e. dental technicians, to be able to work on
casts/models obtained by impression making to fabricate
The current issue and full text archive of this journal is available at precision restorations, usually by traditional waxing or plastic
www.emeraldinsight.com/1355-2546.htm forming and investment casting technology. It is a reality that
the quality and accuracy of the final product however,
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Evolution of rapid prototyping in dentistry: a review Rapid Prototyping Journal
Abbas Azari and Sakineh Nikzad Volume 15 Number 3 2009 216 225
3 Master model
2 Impression 4 Wax up
1 Patient 5 Mould
10 Patient
6 Casting
9 Veneering 7 Devesting
8 Preparation
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Abbas Azari and Sakineh Nikzad Volume 15 Number 3 2009 216 225
Figure 2 A typical device used the non-contact concept complex milling parts. So, another type of machining is
required which can make medical/dental parts (models) with
high precision, as fast as possible and without difficulties
encountered during simple milling.
Laser
digitizing
Note: It uses a detector for the surface and a camera for the textures 1 2
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form of virtual trajectories guiding material additive processes millimeter to 10 or 20 mm, respectively, (Hildebolt et al.,
to physically rapid build up these layers in an automated 1990; Vannier et al., 1984). One of the most prominent
fabrication machine to form the object called the prototype features of computed tomography (CT) scan images is that
(Weiss, 1997) (Figure 6). In this way, the captured 3D data they possess no magnification errors caused by geometric
set, rapidly slice into cross-sections, and construct layers from distortions; while such errors are common in conventional
the bottom up, bonding one on top of the other, to produce dental/medical radiographs (Rosenfeld and Mecall, 1996;
models for applications. It was demonstrated that by using Sonic et al., 1994). The information collected from each plane
this method the overall production time will reduce is numerically analyzed to derive the spatial distribution of the
considerably and complex models which are otherwise X-ray densities within the plane. Information can then be put
difficult and/or impossible to make by the conventional NC together to provide a volumetric image of the structure
machining process could be build up rather easily (Liu et al., (Figures 7 and 8).
2006). Owing to these capabilities, using additive methods for At about the same time, as CT was demonstrated,
Medical Modeling (prototyping) is more advantageous and application of nuclear magnetic resonance as an
many problems usually accompanied by milling can be easily interrogation probe was also demonstrated. The name of
overcome. The main advantage of this type of model this modality evolved over the years to magnetic resonance
manufacturing in building the medical/dental parts is the interferometry (MRI) and then finally to MR scanning. MR
ability of the technique to create minor details such as differs from CT in one major aspect: the MR system is tuned
undercuts, voids, and complex internal geometries to hydrogen, a common constituent in most soft-tissue
(neurovascular canals or sinuses, etc.) in the proposed model. cellular matter. It is assumed that this measurement will
It is obvious however, that gathering information from define the spatial locations of organs by differentiating them
internal structures requires somewhat different steps for data according to the densities of hydrogen within their tissues
capturing which is not possible with merely optical or touch
probe surface capturing devices. This drawback was Figure 7 A typical modern spiral CT scan machine
accidentally resolved by an innovating technology: computer
axial tomography scanning.
Primary
material
Unconnected
region Overhanging
feature
Forms
cavity
feature Slice distance
(a) Complementary support (b) Explicit support
Note: The layer by layer concept
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Abbas Azari and Sakineh Nikzad Volume 15 Number 3 2009 216 225
(Lightman, 1997). The capability of both technique in beginning from the bottom of the model and building up.
providing detailed 3D pictures of the anatomy of the area of As the resin is exposed to the UV light, a thin well-defined
interest and gathering valuable data for diagnostic and layer thickness becomes hardened. After a layer of resin is
therapeutic usage has very soon stimulated many clinicians cured, the resin platform is lowered within the bath by a small
(Chua et al., 1998; Diamantopoulos and Richardson, 2002). known distance. A new layer of resin is wiped across the
It was also exciting that similar to CT scan data, MR scan surface of the previous layer using a wiper blade, and this
data are also computed and presented in a layer-by-layer second layer is subsequently exposed and cured. The process
format. of curing and lowering the platform into the resin bath is
The layer data format of 3D scanners quickly prompted the repeated until the full model is complete. The self-adhesive
realization that it should be possible to convert the data to be property of the material causes the layers to bond to each
compatible with RP machine requirements, i.e. a physical other and eventually form a complete, en bloc 3D object. The
model can be manufactured based on X-ray CT or MRI data. model is then removed from the bath and cured for a further
It is exciting that in spite of availability of CT scanners since period of time in a UV cabinet (Figure 9).
1973 (Hounsfield, 1973), it was not until 1987 that this This technology today is capable of producing highly
innovative technology became available for dental application complex 3D geometries with little or no human intervention
(Schwarz et al., 1987a, b). It is also interesting that the main (Hildebolt et al., 1990). The most significant advantages and
motivating factor for using CT in dentistry is the science of disadvantages commonly relevant to this technique are
oral implantology (Azari and Nikzad, 2008). incorporated in Table II (Hildebolt et al., 1990; Vannier
et al., 1984; Rosenfeld and Mecall, 1996; Sonic et al., 1994;
RP vs medical/dental prototyping Lightman, 1997). Practically, SLA method is best for
educational purposes and rehearsing the best possible
New terms always results from progress and development;
surgical planning before surgery. This capability has been
and so the term medical rapid prototyping (MRP) has been
fully demonstrated from many studies (Bajura et al., 1992;
evolved in the late 1990s. Just as RP, the aim of MRP is to
fabricate dimensionally accurate physical models of human European Commission, 2002; Wouters, 1998). There is also
anatomy derived from medical image data using a variety of some, who clearly demonstrated the possibility to use these
RP technologies. As in many branches of medicine, this term
has been also used in dentistry for a range of dental Figure 9 Principle of SLA
specialties, including oral and maxillofacial prosthodontics
and surgery (Anderl et al., 1994; Arvier et al., 1994; DUrso X-Y movable
et al., 1999; Eufinger and Wehmoller, 1998; Gateno et al., UV light source
Liquid surface
2000; Sailer et al., 1998; Hughes et al., 2003), dental
implantology as a surgical guide or physical model
(Heckmann et al., 2001; Ganz, 2006; Lal et al., 2006;
Formed object
Vrielinck et al., 2003; Ganz, 2005) and prosthodontics (Jeng
on elevator
et al., 2000a, b; Bibb et al., 2006; Eggbeer et al., 2005; Wang
et al., 2002; Li et al., 2000, 2001a, b). The use of RP in dental
branches has many other benefits of which only one of them is
medical modeling construction; there are so many useful
fields in which RP can be helpful, i.e. mass production of
patterns for casting purposes. In this way, time consuming
and/or difficult parts in restoration making can be easily
implemented even without human intervention.
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Abbas Azari and Sakineh Nikzad Volume 15 Number 3 2009 216 225
systems for impression purposes in reconstructive surgeries Figure 11 Schematic of 3DP systems
and sub-periosteal dental implant surgery (Gateno et al.,
2000; Sailer et al., 1998; Golec, 1986; Truitt et al., 1988;
DUrso et al., 2000; Klein et al., 1992; James et al., 1998).
Liquid adhesive
Nowadays, the main objective for using SLA models in
supply
dentistry is fabrication of surgical drilling templates during
dental implant insertion. The high accuracy of SLA-made
surgical drill guides has been proved by several well-
documented studies (van Steenberghe et al., 2002; Sarment Ink jet head
Powder
et al., 2003; Chen et al., 2004) (Figure 10). Furthermore, the Roller bed
transparency of the model and the recent development of
color resins allow distinct visualization of anatomical
structures (Lightman, 1997).
Builded
Inkjet-based system or 3DP model
The working principle of this RP system is basically similar Powder
to the conventional 2D inkjet printer. Initially, a measured delivery Fabrication
quantity of powder is dispensed from a supply chamber by system piston
moving a piston upward incrementally. A roller then
distributes and compresses the powder at the top of the
fabrication chamber. The multi-channel jetting head Table III The main advantages and disadvantages of 3DP systems
subsequently deposits a liquid adhesive in a 2D pattern
onto the layer of the powder, which becomes bonded in the Advantages Disadvantages
areas where the adhesive is deposited, to form a layer of Fast fabrication time Large tolerance
the object. Once a layer is finished, the piston that supports Low material cost Lower strength models
the powder bed and the part lowers so that the next powder Capability of being colored Rough surface finish
layer can be spread and selectively joined. This layer-by-
Build models can be used for
layer technique is gradually continued until the prototype is
casting purposes directly
completely built up. Following a heat-treatment process,
Low toxicity
unbound powder is swept up, leaving the fabricated part
Relative material variety
intact (Lightman, 1997) (Figure 11). The larger tolerance
(0.127 mm) of output model is a problem for delicate dental
models such as casting patterns but for creating educational
models it does matter. Moreover, it seems that due to this surface of a build cylinder. Powder is deposited incrementally
high tolerance, 3DP technology is not as useful for on top of each solidified layer and sintered again. The piston
impression purposes as SLA is. There are a number of in the cylinder moves down one object layer thickness to
potential reasons for the inaccuracies; they can easily break accommodate the new layer of powder. A laser beam is then
off. This may result in additional time for precise fitting of traced over the surface of this tightly compacted powder
medical implants during surgery but, it may helpful for (Figure 12). The process is self-supporting and parts can
rehearsing surgical procedures (Gibson et al., 2006). The
therefore be nested together. The selective nature of the
advantages and disadvantages of the system demonstrated in
lasers enables complex geometries to be achieved without
Table III.
compromising on functionality (Lightman, 1997). The range
Selective laser sintering of thermoplastic materials like nylon composite, investment
SLS is a process of fusing together layers of specified powder casting wax, metallic materials, ceramics and thermoplastic
material into a 3D model by a computer-directed laser. In this composites that can be used on the SLS machine is a big
system, the powdered material is spread by a roller over the
Figure 12 Schematic of SLS technology
Figure 10 SLA made Drill guides for implant surgery
Scanner
system
Laser
Powder
bed
Roller
Powder
delivery Fabrication
Source: Materialise N.V., Leuven, Belgium system piston
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advantage especially in the field of dentistry. The ability of this Figure 13 Schematic illustration of the FDM process
technology to build up removable partial denture (RPD)
frameworks has recently been demonstrated (Jeng et al.,
2000b; Bibb et al., 2006). The material used was cobalt-
chrome spherical powder with a maximum particle size of z
0.045 mm (particle size range 0.005-0.045 mm) and a mean y Thermoplastic or wax
particle size of approximately 0.030 mm. The part proved filament
successful and produced a complete cobalt-chrome RPD
framework (Bibb et al., 2006). The possibility to preheat the x Heated FDM head
SLS machines just below the temperature needed for metal moves in x-y plane
powder sintering (melting) by lasers made this system very
speedy. This minimizes thermal distortion and facilitates Plastic model
fusion to the previous layer (Kai et al., 2000). Some of the created on minutes
basic advantages and disadvantages of this RP technique are
listed in Table IV.
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Corresponding author
mandibular canal, Int. J. Oral Maxillofac. Implants, Vol. 9,
pp. 455-60. Sakineh Nikzad can be contacted at: snikzad@sina.tums.ac.ir
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