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Abstract：Dental casts have been used as a reference standard in orthodontic treatment, however, these traditional plaster casts are subject to degradation, fracture and storage inconvenience. Aiming at the low efficiency and low precision of the plaster casts making process, a practical method of making the dental casts based on 3D printing technology is put forward, and the accuracy of the casts is analyzed by computer-aided measurement. Firstly, the 3D printing dental casts is obtained by fused deposition modeling technique after building digital model of image data. Then the measurement items and measurement standards of accuracy analysis are developed, at the same time, the accuracy of the casts is analyzed using computer-aided measurement and best-fit algorithm. Finally statistical analysis is used to the measurement data and shows the difference distribution. Experimental results show that 3D printing dental casts have clinically acceptable accuracy, and 3D printing technology is more efficient and economical than the traditional production process. The computer aided measurement of dental casts not only replaces the traditional manual measurement method, but also greatly improves the accuracy and efficiency of the measurement, which has the potential to be aplied for clinical pratice.