This study assessed the influence of acquisition parameters of tomographic volumes on the reproduction of thin bone structures for rapid prototyping purposes. Two parameters were investigated: Field of View (FOV) and Slice Thickness (ST). The specimen was comprised of five pairs of 0.6 mm, 1.1 mm, 1.5 mm, 2.0 mm and 2.8 mm thick cortical bone plates. The plates were stuck into utility wax; the first plate of the pair was in vertical position while the second plate was oblique to the first one. Forty-five tomographic images were captured and separated into 3 groups of fifteen images. Each group had a specific FOV: 180 mm; 250 mm and 430 mm, respectively. Within each of these three groups, tomographic slice thickness was varied for every five of the fifteen slices. Acquisitions were carried out with STs of 1 mm, 2.5 mm and 5 mm. The Cyclops Medical Station software was used in the voxel-to-voxel analysis of radiologic density, reaching a total of 1350 assessed images. ST and FOV variation influenced the reproduction of thin bone walls, and FOV was shown to be a very important parameter. The larger the acquisition FOV, the more reduction in the number of voxels within the range of reconstruction for cortical bone in all of the bone plates. The visual analysis of the images of very thin bone walls showed that there could be a sharp drop in the radiologic density value in several adjacent voxels, resulting in areas which might not be reproduced in the reconstruction.
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