Effect of X-Ray Tube Angulations and Digital Sensor Alignments on Profile Angle Distortion of CAD-CAM Abutments: A Pilot Radiographic Study

Abstract

Purpose: This pilot study aimed to evaluate how deviations in X-ray tube head angulation and digital sensor alignment affect the radiographic measurement of the profile angle in CAD-CAM abutments. Materials and Methods: A mandibular model was used with five implant positions (central, buccal, and lingual offsets). Custom CAD-CAM abutments were designed with identical bucco-lingual direction contours and varying mesio-distal asymmetry for the corresponding implant positions. Periapical radiographs were acquired under controlled conditions by systematically varying vertical tube angulation, horizontal tube angulation, and horizontal sensor rotation from 0 degrees to 20 degrees in 5 degrees increments for each parameter. Profile angles, interthread distances, and proximal overlaps were measured and compared with baseline STL data. Results: Profile angle measurements were significantly affected by both X-ray tube and sensor deviations. Horizontal tube angulation produced the greatest profile angle distortion, particularly in buccally positioned implants. Vertical x-ray tube angulations beyond 15 degrees led to progressive underestimation of profile angles, while horizontal tube head rotation introduced asymmetric mesial-distal variation. Sensor rotation also caused marked interthread elongation, in some cases exceeding 100%, despite vertical projection being maintained. Profile angle deviations greater than 5 degrees occurred in multiple conditions. Conclusions: X-ray tube angulation and sensor alignment influence the reliability of profile angle measurements. Radiographs with > 10% interthread elongation or crown overlap may be inaccurate and warrant re-acquisition. Special attention is needed when imaging buccally positioned implants.