Aim: To present an image-processing measurement algorithm to evaluate the transfer accuracy of indirect bonding (IDB) trays, exemplified by a CAD/CAM-based IDB tray integrated into a digital orthodontic workflow.
Materials and methods: Plaster casts of 24 patients with full dentition and different malocclusions were scanned with an intraoral scanner (Trios; 3Shape, Copenhagen, Denmark) to obtain digital models, which served for the virtual placement of orthodontic brackets in simulation software (OnyxCeph; Image Instruments, Chemnitz, Germany). The resulting STL files were sent to a dental laboratory (CA Digital; Hilden, Germany) for the production of INDIVIDUA IDB trays. These trays were used to transfer the brackets to the respective plaster casts. Finally, a second scan was performed to record the actual bracket positions. The transfer accuracy was then analyzed by a measurement algorithm scripted to automation, which calculated the deviations of the planned and real bracket positions with a local best-fit alignment, resulting in three linear and three angular measurements for each bracket.
Results: In total, 622 brackets and tubes were transferred successfully. The presented algorithm analyzed the transfer accuracy and demonstrated that the linear measurements were 98.3% within the range of the American Board of Orthodontics standard. The angular measurements were 86.7% within this range when the INDIVIDUA IDB tray was used.
Conclusion: Scripted measurement algorithms facilitated the evaluation of present and future materials and designs for IDB trays to obtain an efficient solution for orthodontic practice. The INDIVIDUA IDB tray is a digital alternative to conventional IDB trays (Int J Comput Dent 2022;25(3):295–302; doi: 10.3290/j.ijcd.b2599775).