An evaluation of slot size in orthodontic brackets--are standards as expected?

The slots of five upper left central incisor brackets from 11 commercially available bracket systems (3M Unitek, Monrovia, Calif: Twin Torque Roth, Clarity MBT, and Victory Series MBT; Dentarum, Pforzheim, Germany: Discovery Roth (0.56 mm) and Elegance Plastic Roth; Forestadent, Pforzheim, Germany: Mini Mono MBT; TP LaPorte, Indiana: Nu-Edge Roth and Mxi Advant-Edge Roth; Ormco Corp., Orange, Calif: Damon II SL Roth; Ortho Organizers, San Marcos, Calif: Elite Mini Opti-MIM Roth and Elite Mini Opti-MIM MBT) were measured in the 0.022-inch (0.5588 mm) dimension. Measurements were taken after operator calibration, and a digital readout was produced. Results indicate that all bracket slots are oversized. Three bracket systems slots (Twin Torque, Clarity, and Mini Mono) were within 5% (+/-1.08, 1.655, 1.75) of their stated dimensions with essentially parallel slot walls. The Elegance Plastic slot was parallel sided but oversized by 12% (+/-1.15). The geometry of bracket slots was also variable. The Victory Series slot was slightly divergent with the top oversized by 6% (+/-1.035). The Nu-Edge slot was divergent and slot top oversized by 14% (+/-1.32). The Mxi Advant-Edge, Damon II SL, Elite Mini Opti-MIM Roth, and MBT were all convergent, and the base of the Damon slot was oversized by 17% (+/-1.79). The Discovery bracket was convergent, and the slot base was oversized by 24% (+/-1.255), which was the largest recorded variance. This bracket also had a 7% difference between the widths of the slot top and the base. Inaccurate machining of bracket slot dimensions and the use of undersized archwires may directly and adversely affect three-dimensional tooth positioning.