Data Sheet 1_Effect of 3D-printed model base height on thickness distribution of thermoformed zendura FLX dual-layer clear aligners: an in vitro study.xlsx

Post-hoc pairwise comparisons were performed using Tukey's test, with significance set at p < 0.05.</p>Results<p>EMM thickness decreased progressively with increasing MBH: 446 µm (95% CI 432–460) at MBH 2 mm, 386 µm (95% CI 374–399) at MBH 4 mm, 329 µm (95% CI 319–340) at MBH 6 mm, and 268 µm (95% CI 260–277) at MBH 8 mm (all pairwise comparisons p < 0.001). This decreasing trend was consistent across all tooth types and measurement sites, though the magnitude of reduction varied by site.

Palatal sites consistently exhibited greater thickness than facial sites. For most tooth type–site combinations, all MBH contrasts were statistically significant, with limited exceptions observed at specific sites for anterior teeth, molars, and premolars.</p>Conclusions<p>Increasing MBH resulted in a progressive reduction in the thickness of thermoformed Zendura FLX dual-layer clear aligners across all tooth types and measurement sites.

Among the four levels tested, an MBH of approximately 4 mm appeared to provide a more balanced thickness distribution. These findings suggest that MBH should be considered as an important fabrication parameter in clear aligner production.</p>