Fabricating a screw-retained, complete arch, fixed implant prosthesis using selective metal laser sintering: A clinical report

Influence of the implant scan body modifications on trueness of digital impressions

Background/purpose

Effects of implant angulation on digital impression accuracy remain controversial. The purpose of this study was to assess the relationship between the alteration of implant scan bodies and the trueness of digital impressions.

Materials and methods

A maxillary typodont without the right premolars and first molar was scanned with a laboratory scanner and saved as a standard triangular language (STL) file. A model from the STL file was fabricated with a 3-dimensional printer. Two implants were placed into the first premolar and first molar sites of the model, followed by the insertion of two scan bodies onto the implants. These scan bodies were divided into four test groups, based on the surface modifications. A digital impression of each typodont was made with three different intraoral scanners. An abutment was digitally seated on each implant. 120 STL files (30 for each group) of the typodont with two implants and two corresponding abutments were used for statistical analysis.

Results

A total of 240 values (two implants for each typodont) were obtained after each sample (4 groups) was scanned 10 times by utilizing three intraoral scanners. The overall linear and angular discrepancies were analyzed. Group 1 showed the lowest linear discrepancy of 14.9 ± 5.4 μm while Group 4 reported the highest linear discrepancy of 137.5 ± 41.7 μm, yielding a statistical significance (P < 0.05).

Conclusion

It has been concluded that the more adjustments made to the scan bodies, the greater the linear and angular deviations occur, compromising the trueness of the digital implant impression.

Development of AM Technologies for Metals in the Sector of Medical Implants

Additive manufacturing (AM) processes have undergone significant progress in recent years, having been implemented in sectors as diverse as automotive, aerospace, electrical component manufacturing, etc. In the medical sector, different devices are printed, such as implants, surgical guides, scaffolds, tissue engineering, etc. Although nowadays some implants are made of plastics or ceramics, metals have been traditionally employed in their manufacture. However, metallic implants obtained by traditional methods such as machining have the drawbacks that they are manufactured in standard sizes, and that it is difficult to obtain porous structures that favor fixation of the prostheses by means of osseointegration. The present paper presents an overview of the use of AM technologies to manufacture metallic implants. First, the different technologies used for metals are presented, focusing on the main advantages and drawbacks of each one of them. Considered technologies are binder jetting (BJ), selective laser melting (SLM), electron beam melting (EBM), direct energy deposition (DED), and material extrusion by fused filament fabrication (FFF) with metal filled polymers. Then, different metals used in the medical sector are listed, and their properties are summarized, with the focus on Ti and CoCr alloys. They are divided into two groups, namely ferrous and non-ferrous alloys. Finally, the state-of-art about the manufacture of metallic implants with AM technologies is summarized. The present paper will help to explain the latest progress in the application of AM processes to the manufacture of implants.