A Comparative Analysis of Plaster Model Preparation and Intraoral 3D Scanning Techniques in Orthodontic Dental Arch Modeling

Background: Orthodontic treatment relies on accurate dental arch models for diagnosis and treatment planning. Traditional plaster model preparation, though widely used, is associated with potential inaccuracies, patient discomfort, and inefficiency. Aims: This study aimed to compare the accuracy, time consumption, and patient comfort between conventional plaster model preparation and intraoral 3D scanning for orthodontic dental arch modeling. Materials and Methods: This comparative study included 60 participants. Each underwent both plaster model fabrication and intraoral 3D scanning. Model accuracy was evaluated using 3D root-mean-square error after registration. The time required for each method and patient comfort levels (rated as comfortable, generally comfortable, or uncomfortable) were recorded and statistically analyzed. Results: The accuracy of intraoral 3D scanning (0.050 ± 0.001 mm) was not significantly different from that of plaster models (0.050 ± 0.011 mm) ( P = 0.406). However, intraoral scanning was significantly faster (8.297 ± 0.554 min vs. 20.240 ± 1.516 min, P < 0.001) and resulted in significantly higher patient comfort ( P < 0.001). Conclusion: Intraoral 3D scanning technology demonstrates comparable accuracy to traditional plaster modeling while offering substantial advantages in operational efficiency and patient comfort, positioning it as a superior standard for dental arch modeling in orthodontics.