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The purpose of this study is to obtain the optimal three-dimensional (3D) printing condition through the accuracy evaluation of the protective dental splints (PDSs) produced using 3D printed dental casts under various conditions.

The dental casts of dentiform were made using the conventional method and three digital methods. The three 3D printers used one or two materials for each, and the density of the material was varied to find the appropriate printing condition. PDSs were fabricated by the same method using vacuum former on conventional dental casts, and 3D printed dental casts. PDSs were mounted on a dentiform, and the accuracy was measured according to the criteria.

All of the PDSs fabricated using the traditional method showed the highest accuracy, whereas the PDSs made using 3D printed casts showed accuracies that varied with the type of printer, material characteristics and printing density. Achieving the accuracy required for 3D printed dental casts to be used as protective dental devices made with a vacuum former requires appropriate materials and 3D printing density. The findings of this study can be used when making 3D printed models and individual PDSs through intraoral scanning for patients in whom it is difficult to take impressions using traditional methods.

When a digital device is applied to the fabrication of PDSs, it has the advantage of saving time and materials and preventing damage to teeth and periodontal tissue that may occur during the conventional method.