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This in vitro study aims to explore the effects of selective laser melting (SLM) process parameters on the accuracy of the intaglio surface of cobalt–chromium alloy (Co–Cr), commercially pure titanium (CP Ti) and titanium alloy (Ti–6Al–4V) maxillary removable partial denture (RPD) frameworks and optimize these process parameters.

Maxillary RPD framework specimens designed on a benchmark model were built. The process parameters, including contour scan speed and laser power, infill scan speed and laser power, hatch space, build orientation and metallic powder type, were arranged through the Taguchi design. Three-dimensional deviations of the clasps area, connector area and overall area of maxillary RPD frameworks were analyzed by using root mean square (RMS) as a metric. One-way analyses of variance with the above RMSs as the dependent variable were carried out (α = 0.05).

Maxillary RPD frameworks built horizontally had a more accurate intaglio surface than those built at other orientation angles; CP Ti or Ti–6Al–4V maxillary RPD frameworks had a more accurate intaglio surface than Co–Cr ones; the Maxillary RPD framework built with a higher infill scan speed and lower infill laser power had the more accurate intaglio surface than the one built with other levels of these two process parameters.

A novel benchmark model for evaluating the accuracy of the intaglio surface of maxillary RPD frameworks manufactured by SLM is proposed. The accuracy of the intaglio surface of maxillary RPD frameworks can be improved by adjusting SLM process parameters. The optimal setting of process parameters concerning the accuracy of the intaglio surface of maxillary RPD frameworks was given.

This paper aims to improve the efficiency and the quality of metal dental prostheses, reporting on the first patient‐fitted titanium (Ti) complete denture base plate fabricated by integrating the technologies of computer‐aided design and computer‐aided manufacture (CAD/CAM) and laser rapid forming (LRF).

To make a complete Ti denture base plate, the traditional lost‐wax‐casting technique is commonly used in dentistry. In order to simplify this labor‐intensive process, a new method combined with LRF was invented. Initially, a maxillary edentulous plaster cast was converted to point cloud data by laser scanning system. Subsequently, point cloud data were reconstructed into a 3D solid digital cast, which is stored in standard triangulation language format. Thereafter the 3D denture base was sliced electronically into a sequence of layers defining the regions of the component and, based on it, the complete Ti denture base plate was built layer‐by‐layer using a laser additive manufacturing technology.

After CAD/CAM/LRF process, the Ti denture base plate was designed and successfully fabricated layer‐by‐layer. After the traditional dental finishing techniques, the complete Ti denture base plate was made and assessed by clinician and patient. The clinical evaluation on quality of fit was judged to be acceptable.

The CAD/CAM/LRF system is a potential candidate to replace the traditional lost‐wax‐casting technique and provides a new platform for the design and manufacturing of custom‐made Ti denture plates and other restorations especially for implant substructure and framework of partial removal of denture.

The purpose of this paper is to explore an application of computer‐aided design and manufacture (CAD/CAM) to a process of electronically surveying a scanned dental cast as a prior stage to producing a sacrificial pattern for a removable partial denture (RPD) metal alloy framework.

With the introduction of laser scan technology and commercial reverse engineering software, a standard plaster maxillary dental cast with dentition defect was successfully scanned and created as a STL‐formatted digital cast. With the software, the unwanted undercuts were eliminated based on the desired path of insertion. Parts of the RPD framework were then successfully custom‐designed and combined as a whole.

A sacrificial pattern was produced by rapid prototyping (RP) method and finally casted with chromium cobalt alloy. With suitable finishing process, both the sacrificial pattern and the casted framework fitted the cast well.

The research indicated the feasibility of creating a library of RPD framework components. It is believed that, in the future, with the advance of the techniques, a totally new platform can be developed for the design and fabrication of custom‐fit RPD framework based on the CAD/CAM/RP system.

Three-dimensional (3D) printing technologies have gained attention in dentistry because of their ability to print objects with complex geometries with high precision and accuracy, as well as the benefits of saving materials and treatment time. This study aims to explain the principles of the main 3D printing technologies used for manufacturing dental prostheses and devices, with details of their manufacturing processes and characteristics. This review presents an overview of available 3D printing technologies and materials for dental prostheses and devices.

This review was targeted to include publications pertaining to the fabrication of dental prostheses and devices by 3D printing technologies between 2012 and 2021. A literature search was carried out using the Web of Science, PubMed, Google Scholar search engines, as well as the use of a manual search.

3D printing technologies have been used for manufacturing dental prostheses and devices using a wide range of materials, including polymers, metals and ceramics. 3D printing technologies have demonstrated promising experimental outcomes for the fabrication of dental prostheses and devices. However, further developments in the materials for fixed dental prostheses are required.

3D printing technologies are effective and commercially available for the manufacturing of polymeric and metallic dental prostheses. Although the printing of dental ceramics and composites for dental prostheses is promising, further improvements are required.

Medical devices are undergoing rapid changes because of the increasing affordability of advanced technologies like additive manufacturing (AM) and three-dimensional scanning. New avenues are available for providing solutions and comfort that were not previously conceivable. The purpose of this paper is to provide a comprehensive review of the research on developing prostheses using AM to understand the opportunities and challenges in the domain. Various studies on prosthesis development using AM are investigated to explore the scope of integration of AM in prostheses development.

A review of key publications from the past two decades was conducted. Integration of AM and prostheses development is reviewed from the technologies, materials and functionality point of view to identify challenges, opportunities and future scope.

AM in prostheses provides superior physical and cognitive ergonomics and reduced cost and delivery time. Patient-specific, lightweight solutions for complex designs improve comfort, functionality and clinical outcomes. Compared to existing procedures and methodologies, using AM technologies in prosthetics could benefit a large population.

This paper helps investigate the impact of AM and related technology in the field of prosthetics and can also be viewed as a collection of relevant medical research and findings.

The purpose of this study is to develop and apply clinically relevant methods of analysing the accuracy of dental appliances fabricated using additive manufacture (AM) compared to the computer-aided design (CAD) geometry. The study also compared fit between conventionally laboratory-fabricated and AM-produced base plates.

The techniques were applied to two types of dental devices where AM fabrication methods could foreseeably be used as an alternative to laboratory production. “L” and cubic shapes of defined dimensions and spatial locations were positioned on the devices which were fabricated using AM. For assessing the dimensions, the “L” and cubic shapes were then measured on the physical builds ten times and compared to the CAD model. To assess the fit of AM and lab-produced devices, three upper and three lower conventionally fabricated acrylic base plates were compared to three upper and three lower plates. Silicone impression material was allowed to set between the casts and the base plates which filled any discrepancy between the two surfaces. The thickness of this silicone media was measured ten times at five different points on each base plate type and the results compared.

The results indicated that the evaluated CAD/AM technique is able to produce dental appliance components that are consistent with tolerance levels that would be expected with conventional methods of baseplate design. This research demonstrated that a fully CAD/AM methodology represents a potentially viable alternative to conventional lab-based methods for two types of dental appliances.

This work is original. The authors do not believe any previous papers similar to the one submitted have been published.

The purpose of this paper is to analyse structure and measure hardness of Co-Cr dental alloy samples made with two different technologies, conventional casting method (CCM samples) and additive direct metal laser sintering technology (DMLS samples), and to compare the results.

CCM samples were made in a conventional casting machine, using remanium 800+ Co-Cr dental alloy (Dentaurum, Ispringen, Germany). DMLS samples were fabricated out of EOS CC SP2 Co-Cr alloy (EOS, GmbH, Munich, Germany) using DMLS technology. Samples for structural analysis were plate-shaped (10 × 10 × 1.5 mm3) and for the hardness test were prismatic-shaped (55 × 10.2 × 11.2 mm3). Structure was analysed via an inverting microscope and colour metallography method.

CCM samples have a dense, irregular dendritic mesh, which is typical for the metallic phase of the Co-Cr dental alloy. DMLS alloy has a more homogenous and more compact structure, compared to CCM. Metals, the alloy basis consists of, form semilunar stratified layers, which are characteristic for the additive manufacturing (AM) technique. Hardness values of DMLS (mean value was 439.84 HV10) were found to be higher than those of CCM (mean value was 373.76 HV10).

There are several reports about possible use of AM technologies for manufacturing dental devices, and investigation of mechanical properties and biocompatibility behaviour of AM-produced dental alloys. Microstructure of Co-Cr alloy made with DMLS technology has been introduced for the first time in the present paper.

Digitalization and additive manufacturing now play an important role in the manufacturing of medical and dental products. The purpose of this paper is to present the results of the treatment of skeletal Class II malocclusion in a growing patient using fixed sagittal guidance (FSG) appliance manufactured by digital and fast procedure by selective laser melting.

This study present the case of a 14-year-old boy with a convex profile owing to a retrognathic mandible, an overjet (8 mm), a deep overbite (7 mm), a Class II canine, a molar relationship on both sides and an accentuated lower curve of Spee. The lateral cephalogram showed a skeletal Class II discrepancy with mandibular retrognathia, skeletal deep bite, reduced lower anterior facial height and proclined upper incisors. Treatment using FSG and fixed orthodontic appliance was performed within 15 months.

The final results show a well-balanced face and a nice profile. Protrusion of the maxillary anterior teeth was corrected, and a Class I molar relationship was achieved with proper overjet and overbite.

The results from the proposed method are promising, although long-term results with a large group are not yet available.

Using an individually made FSG appliance from biocompatible material and an individualized treatment plan, an effective result in treating Class II malocclusion due to retrognathic mandible with favorable dentofacial effects has been achieved.

This is the first paper describing the use of additive manufacturing for orthodontic appliances in Slovenia.