This study evaluated the accuracy of reproduction of stone casts made from impressions using different tray and impression materials. The tray materials used were an acrylic resin, a thermoplastic, and a plastic. The impression materials used were an additional silicone, a polyether, and a polysulfide. Impressions were made of a stainless steel master die that simulated crown preparations for a fixed partial denture and an acrylic resin model with cross-arch and anteroposterior landmarks in stainless steel that typify clinical intra-arch distances. Impressions of the fixed partial denture simulation were made with all three impression materials and all three tray types. Impressions of the cross-arch and anteroposterior landmarks were made by using all three tray types with only the addition reaction silicone impression material. Impressions were poured at 1 hour with a type IV dental stone. Data were analyzed by using ANOVA with a sample size of five. Results indicated that custom-made trays of acrylic resin and the thermoplastic material performed similarly regarding die accuracy and produced clinically acceptable casts. The stock plastic tray consistently produced casts with greater dimensional change than the two custom trays.
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