CAD/CAM indirect bonding trays using hard versus soft resin material: a single-blinded in vitro study.

OBJECTIVES: The present in vitro study aimed to evaluate the accuracy of three-dimensional (3D) printed indirect bonding trays consisting of hard or soft resin materials produced using computer-aided design and manufacturing (CAD/CAM). METHODS: Forty-eight dental casts were 3D printed. Four groups based on frontal crowding were defined and divided into hard- and soft-resin groups. After virtual bracket positioning on the digital models, the transfer trays were 3D printed. To evaluate the accuracy of the procedure, measurements were performed using a digital overlay of the virtual (target) bracket position and a post-bonding scan. The horizontal, transverse, and vertical deviations and angular discrepancies were analyzed. The loss rate was evaluated descriptively as a percentage. RESULTS: A total of 553 brackets were bonded using 24 soft and 24 resilient indirect bonding trays. The mean deviations were of 0.05 mm (transversal), 0.05 mm (horizontal), 0.09 mm (vertical), 0.13 degrees (angulation) in the resilient resin group and of 0.01 mm (transversal), 0.08 mm (horizontal), 0.08 mm (vertical), 0.37 degrees (angular) in the soft resin group. The loss rate was 6.9% and 0.7% in the hard and soft resin groups, respectively. Angular deviations were significantly higher in the soft resin group (P = 0.009), whereas the loss rate was considerably higher in the hard resin group (P < 0.001). SIGNIFICANCE: The findings indicate that indirect bonding using CAD/CAM is an accurate procedure in the laboratory setting. Soft resins are considered favorable for loss rate and useability.