Effect of Pixel Offset Adjustments for XY Plane Dimensional Compensation in Digital Light Processing 3D Printing on the Surface Trueness and Fit of Zirconia Crowns

This study aimed to evaluate the effect of pixel offset adjustments in digital light processing (DLP) three-dimensional (3D) printing on the marginal and internal fit and surface trueness of zirconia crowns. Zirconia crowns were designed using dental computer-aided design software (Dentbird; Imagoworks) and fabricated with a vat photopolymerization DLP 3D printer (TD6+; 3D Controls) under three pixel offset conditions (−1, 0, and 1). Pixel offset refers to the controlled modification of the outermost pixels in the XY plane during printing to compensate for potential dimensional inaccuracies. The marginal and internal fit was assessed using a triple-scan protocol and quantified using root mean square (RMS) values. Surface trueness was evaluated by measuring RMS, positive and negative errors between the designed and fabricated crowns. Statistical analyses included one-way ANOVA and Pearson correlation analysis (α = 0.05). The Pixel offset had a significant effect on fit accuracy and surface trueness (<i>p</i> < 0.05). Higher pixel offsets increased marginal discrepancies (<i>p</i> = 0.004), with the marginal gap exceeding 120 µm at a pixel offset of 1 (114.5 ± 14.6 µm), while a pixel offset of −1 (85.5 ± 18.6 µm) remained within acceptable limits (<i>p</i> = 0.003). Surface trueness worsened with increasing pixel offset, showing greater positive errors (<i>p</i> < 0.001). Optimizing pixel offset in DLP 3D printing is crucial to ensuring clinically acceptable zirconia crowns. Improper settings may increase marginal discrepancies and surface errors, compromising restoration accuracy.