Multi-Objective Analysis of Printing Parameters of Long-Term Mechanical Performance of DLP-Based Resins for Fabrication of Orthodontic Retainers

Introduction: Optimization of DLP (digital light processing) printing parameters to improve the long-term durability of fabricated orthodontic retainers is essential for enhancing oral health, reducing waste, and promoting sustainable manufacturing practices, thereby contributing to the UN Sustainable Development Goals. However, depending on the printing parameters used, the mechanical properties of printed retainers can vary significantly. Methods: Twelve specimens fabricated using the combination of optimal parameters for enhanced mechanical performance were used as the basis for the multi-objective optimization approach of the current study. Several mechanical tests, including compressive strength and surface roughness, were performed to assess the mechanical properties of printed retainer materials. Different combinations of printing parameters were analyzed statistically to determine the significance of the observed disparities. Results: The optimized parameters (e.g., layer height: X microns, orientation angle: Y degrees, curing time: Z minutes) resulted in an [X%] increase in compressive strength and a [Y%] reduction in surface roughness compared to baseline/unoptimized conditions. Experimental validation of the predicted results showed minor error percentages, with optimized results at a layer height of 90.1185, orientation angle of 89.9987, and curing time of 99.9921, yielding a compressive strength of 293.6757 and surface roughness of 0.28838. Discussion: The optimized DLP printing parameters significantly improved the mechanical strength and surface finish of orthodontic retainers, indicating enhanced durability, reduced material defects, and better clinical reliability. Future studies may explore a broader range of material types and parameter variations. Conclusion: The results of the present study can be used by orthodontic professionals and manufacturers to enhance the mechanical properties of printed retainers, optimize the printing process, and improve the long-term performance of patented orthodontic retainers. conclusion: The findings provide a basis for orthodontic professionals and manufacturers to optimize the DLP printing process, leading to improved mechanical properties and long-term performance of orthodontic retainers, contributing to enhanced oral health and sustainable manufacturing.