Additive Manufacturing (AM) is increasingly being used in healthcare sectors for its potential to fabricate patient-specific customized implants, and specifically in dentistry, AM finds its applications in maxillofacial implants, dentures, and other prosthetic aids. However, in most applications, AM is largely being used for prototyping purposes. The full-scale realization of AM can only be achieved if the downsides of AM are addressed and resolved. Hence this paper focuses on providing a detailed analysis of surface quality, dimensional accuracy, and mechanical properties of the biocompatible material produced, using the Stereolithography (SLA) method for a dental application. For quality analysis, test artefacts were produced, and the quality was assessed before and after the sterilization process. The results suggest that micro-surface roughness essential for cell growth is similar for all build inclinations and well within the control limit required for effective bone regeneration. Multi-scale surface characterization revealed that the sterilization process involving heat can potentially alter the micro-roughness features of resin-based materials. The results from the dimensional analysis show that the SLA parts produced had negligible dimensional deviations from the CAD model to the printed parts and were unaffected by the sterilization process. The tensile test results suggest that the part orientation does not affect the tensile strength and that the sterilization process seems to have an insignificant effect on the tensile properties of the SLA parts. Furthermore, the results were validated by producing a membrane barrier for Guided Bone Regeneration (GBR). The validation results showed that excess resin entrapment was due to the geometrical design of the membrane barrier. In conclusion, this paper provides an overview of quality variations that can help in optimizing the AM and sterilization process to suit dental needs. © 2023 IOP Publishing Ltd.