Document Type

Article

Publication Date

Winter 12-2025

Abstract

Objectives: To compare the accuracy of fit, surface roughness, and microstructure of cobalt chromium (Co-Cr) maxillary removable partial denture (RPD) frameworks fabricated using direct metal laser melting (DMLS) and selective laser melting (SLM). Methods: A custom Kennedy Class II maxillary partial edentulous resin model was digitally scanned, and a virtual RPD framework was designed. Frameworks were fabricated using DMLS (Co-Cr, n = 8) and SLM (Co-Cr, n = 8), while a control group was produced using a hybrid digital-conventional protocol by lost-wax casting (CAST-Co- Cr, n = 8), in total 24 frameworks. Overall and point comparison adaptation was assessed using Geomagic Control X software program, surface roughness and microstructure were analyzed using scanning electron microscope (SEM). Group comparisons were performed using one-way ANOVA, with Tukey HSD post-hoc tests (significance at p ≤ 0.05). Results: Quantitative analysis revealed significant differences in 3D accuracy among fabrication techniques (p < 0.001). DMLS frameworks demonstrated superior overall fit (170 ± 1μm) and rest seat adaptation (144.9 ± 87.0 μm) compared to CAST (194 ± 17 μm and 392.6 ± 166.1 μm, respectively, p ≤ 0.003), with SLM showing intermediate values (182 ± 14 μm and 237.4 ± 151.6 μm). Surface topography analysis indicated DMLS had significantly lower roughness (54.1 ± 8.0 μm) than SLM (87.3 ± 9.8 μm) and CAST (83.4 ± 10.4 μm, p ≤ 0.003), with no SLM-CAST difference (p = 0.734). Conclusions: DMLS 3D printing method produced Co-Cr RPD frameworks with superior fit accuracy and smoother surfaces compared to SLM 3D printing and traditional casting techniques. conclusion Clinical significance: The comparison between DMLS and SLM 3D printing techniques for the fabrication of RPD frameworks offers significant insights for clinical practice in prosthodontics. Both techniques present a promising alternative to traditional metalworking methods, with potential improvements in precision, customization, and material strength.

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