Effect of finish line design and metal alloy on the marginal and internal gaps of selective laser melting printed copings

Comparison of the overall fit of three-unit posterior fixed dental prostheses fabricated with laser sintering and conventional casting methods

OBJECTIVES

The aim of this study was to investigate the marginal, internal, and occlusal discrepancies of three-unit posterior cobalt-chromium (Co-Cr) fixed dental prostheses (FDPs) produced using five different fabrication techniques.

MATERIALS AND METHODS

Segmental maxillary models were prepared from polyamide material using a laser sintering method. The maxillary first premolar and first molar teeth were prepared to receive posterior FDPs. Direct metal laser sintering (DMLS) and selective laser melting (SLM) were used as two metal laser Co-Cr framework production systems. FDP specimen patterns were prepared by manual wax carving (Cast), 3D-printed polymer (3DP), and CAD/CAM wax and cast using the lost-wax technique as conventional methods. In total, 100 Co-Cr metal framework specimens were prepared for posterior FDPs (n = 20). The silicone replica technique was used to measure marginal, internal, and occlusal discrepancies of all frameworks. A stereomicroscope was employed to detect discrepancies at 100× magnification. The data were analyzed using two-way ANOVA (α = 0.05) and post hoc Bonferroni adjustment (α = 0.005) for pairwise comparisons.

RESULTS

There were no significant differences between the occlusal discrepancy values of premolar abutments of FDPs when compared with different fabrication methods (P > 0.05). The highest marginal discrepancy value was detected as 116.22 μm for molar abutment when the Cast method was used (P < 0.05). The highest occlusal discrepancy values were detected as 135.60 μm and 141.49 μm for molar abutments of posterior FDPs when the 3DP and Cast methods were used. The lowest marginal discrepancy value was detected as 38.94 μm for molar abutments when the DMLS method was used (P < 0.05).

CONCLUSIONS

The DMLS method was more successful than other fabrication methods when fit values of abutment teeth for posterior frameworks were compared.

CLINICAL RELEVANCE

The morphology of the abutment teeth and the fabrication techniques of FDPs migth affect the discrepancy values of FDPs planned. It was seen that the discrepancy values were lowest with the DMLS and SLM methods. Considering the results of this in-vitro study, DMLS and SLM techniques may be more appropriate option than the 3DP method, which starts with digital design and ends conventionally casting technique for posterior three-unit FDPs.

Mechanical properties of 3D printed prosthetic materials compared with milled and conventional processing: A systematic review and meta-analysis of in vitro studies

STATEMENT OF PROBLEM

Three-dimensional (3D) additive manufacturing (AM) is an evolving technology in dentistry, proposed as an alternative to subtractive milling manufacture (MM) or conventional processing. However, a systematic review of the use of AM technology instead of milling or conventional processing is lacking.

PURPOSE

The purpose of this systematic review and meta-analysis was to evaluate the mechanical properties of 3D printed prosthetic materials compared with MM and conventional techniques.

MATERIAL AND METHODS

An electronic search of the literature was conducted on the MEDLINE (via PubMed), Scopus, and Web of Science databases. The inclusion criteria were in vitro studies published in the last 5 years, in English or Italian, and with 3D AM printed dental prosthetic materials. Data extraction was focused on dental prosthetic materials (ceramics, polymers, and metals) and their mechanical properties: flexural strength, fracture load, hardness, roughness, removable partial denture (RPD) fit accuracy, trueness, marginal discrepancy, and internal fit. Data considered homogenous were subjected to meta-analysis using the Stata17 statistical software program (95% confidence interval [CI]; α=.05). Since all variables were continuous, the Hedge g measure was calculated. A fixed-effects model was used for I2=0%, while the statistical analysis was conducted using a random-effects model with I2>0%.

RESULTS

From a total of 3624 articles, 2855 studies were selected, and 76 studies included after full-text reading. The roughness of AM-printed ceramics generally increased compared with that of conventional processing while the marginal discrepancy was comparable both for ceramics and polymers. The flexural strength, hardness, and fracture load of AM-printed polymers were statistically lower than those of the conventional group (P<.05). No significant difference was detected in terms of hardness, roughness, marginal discrepancy, fracture load, trueness, or internal fit between the AM and MM techniques (P>.05). Milling techniques showed significantly higher values of flexural strength (Hedge g=-3.88; 95% CI, -7.20 to -0.58; P=.02), also after aging (Hedge g=-3.29; 95% CI, -6.41 to -0.17; P=.04), compared with AM printing.

CONCLUSIONS

AM is comparable with MM in terms of mechanical properties, in particular with polymeric materials. The flexural strength of AM-printed prostheses is lower than with conventional and MM techniques, as are the parameters of hardness and fracture load, while the marginal discrepancy is similar to that of MM and conventional techniques. AM prostheses are commonly used for interim crowns and fixed partial dentures, as their rigidity and fracture resistance cannot support mastication forces for extended periods. More comparative studies are needed.

Influence of various fabrication techniques and porcelain firing on the accuracy of metal-ceramic crowns

BACKGROUND

The fit of a metal-ceramic restoration is essential to its long-term durability. Regarding marginal and internal fit, there is not enough information about the technologies used in the production of metal-ceramic restorations. The aim of this in vitro study is to compare, both before and after porcelain firing, the marginal, axial, axio-occlusal, and occlusal fit of metal-ceramic restorations manufactured using casting, additive or subtractive computer-aided design, and computer-aided manufacturing techniques (CAD/CAM).

METHODS

CAD/CAM were used to create 50 prepared maxillary first molar-shaped Co-Cr die models, which were randomly divided into 5 groups (n = 10). Cobalt-chrome copings were produced by casting (C), hard metal milling (HM), soft metal milling (SM), selective laser melting (SLM), and selective laser sintering (SLS) techniques. Before and after porcelain firing, discrepancies of the copings were measured using the silicone replica technique. The data obtained by measurements with a stereomicroscope at x80 magnification were analyzed statistically in the SPSS program. The ROBUST three-way analysis of variance (ANOVA) method was used to compare the discrepancy values.

RESULTS

There were statistically significant differences among fabrication methods (P < .001). The HM method showed the highest discrepancy (90.1 μm), and the C (63 μm) method showed the lowest discrepancy in terms of the die model- crown fit. The C, SLS, and SM methods (63 μm; 61.6 μm; 67.7 μm) were statistically similar (P > .001). The highest discrepancy was observed on the occlusal area (87.1 μm), and the lowest discrepancy was observed on the axial area (47.7 μm) of the coping. Porcelain firing had a decrease in the discrepancy values (P = .001).

CONCLUSION

All CAD/CAM techniques are appropriate for clinical use; selective laser sintering and soft milling can be the more recommended methods for the compatibility of metal-porcelain restorations, as they have lower discrepancy values than the SLM and HM methods.

Effect of finish line location and saliva contamination on the accuracy of crown finish line scanning

PURPOSE

Intraoral scanners are used widely as an alternative to conventional impressions, but studies on the influence of finish line location and saliva contamination on scanning trueness are lacking. The purpose of this in vitro study was to evaluate the influence of finish line location and saliva contamination on the scanning trueness of crown finish lines.

MATERIALS AND METHODS

Three ivorine teeth were prepared for all-ceramic crowns with finish lines placed equigingivally, 0.5 mm subgingivally, and 1.0 mm subgingivally. A single-cord technique was used for gingival retraction, and a total of 180 intraoral scans were made using two intraoral scanners (Emerald; Planmeca USA Inc., Hoffman Estates, IL, USA & Trios 3; 3Shape A/S, Copenhagen, Denmark). The prepared teeth were separated from the dentoform and scanned using the same intraoral scanners to create reference scans. All scans were imported to the design software (Dental System 2019; 3Shape A/S, Copenhagen, Denmark). After marking the finish lines of prepared teeth, intraoral scans were aligned to the reference scans for comparisons. Vertical and horizontal marginal discrepancies were measured at four different measuring points (buccal, lingual, mesial, and distal) and analyzed. Two-way ANOVA and Tukey HSD tests were used for statistical analysis (α = 0.05).

RESULTS

The average vertical and horizontal discrepancies from various groups ranged from -33 to 440 µm. For both intraoral scanners, subgingival finish line groups showed greater vertical and horizontal discrepancies compared with equigingival finish line groups. Saliva contamination significantly increased both vertical and horizontal discrepancies for all finish line locations. The discrepancy increases due to saliva contamination were greater for the subgingival groups.

CONCLUSIONS

Subgingival finish lines were not accurately captured using the intraoral scanners. The presence of saliva significantly reduced scanning trueness, and this was amplified when the finish lines were located subgingivally.

The effect of repeated porcelain firings on the marginal fit of millable and conventional casting alloys

The durability of dental restorations is highly determined by an accurate marginal fit, which is in turn affected by the high temperature of porcelain firing. Information is inadequate about the marginal adaptation of metal-ceramic restorations fabricated by soft metal milling technologies after repeated firings. This study aimed to compare the effect of repeated ceramic firings on the marginal fit of copings fabricated from cobalt-chromium through soft metal milling and a conventional nickel-chromium casting alloy. A single standard brass die was designed, machined, and scanned, based on which, 20 frameworks were designed and fabricated through either soft metal milling or conventional casting (n = 10 per group) and porcelain veneered. The vertical marginal fit of the metal copings was measured after 3, 5, and 7 firing cycles by using a digital microscope on 16 points around the finish line of the metal die at ×80 magnification. The data were analyzed through repeated measures ANOVA and independent t-test (α = 0.05). The marginal fit of neither metal group was significantly affected by the number of firing cycles (P = 0.747). However, the marginal discrepancy was statistically lower in the soft metal milling group than that in the casting group (P<0.001). Repeated porcelain firings did not significantly affect the marginal fit of either alloy and remained within the clinically acceptable range after firings. However, the milled alloy had superior marginal fit regardless of the number of firing cycles.

Marginal Misfit of 3D-Printed (Selective Laser Sintered), CAD-CAM and Lost Wax Technique Cobalt Chromium Copings with Shoulder and Chamfer Finish Lines: An In-Vitro Study

Background and Objectives: The aim was to compare the Misfit of 3D-Printed, Selective laser melting (SLM), milled (Computer aided design-Computer aided manufacture CAD-CAM) and Lost wax technique (LWT) fabricated Cobalt chromium (CoCr) alloy copings on shoulder (SH), radial shoulder (R-SH) and chamfer (CH) finish line configuration. Materials and Methods: Ninety resin, second maxillary premolar teeth were prepared for metal-ceramic crowns, equally divided into (n = 30) SH, R-SH and CH margin preparations. For each preparation design (SH, R-SH and CH), CoCr copings were prepared using SLM, CAD-CAM and LWT. This resulted in nine study groups with 10 CoCr copings each. The marginal misfit of specimens was assessed with a high-resolution digital microscope. Misfit was evaluated in vertical and horizontal dimensions in μm. Data were analyzed using ANOVA and a post hoc multiple comparisons test. Results: For vertical misfit, the highest was observed in SLM samples with chamfer margin (167.96 ± 24.1), and the least was shown by CAD-CAM samples with radial shoulder (58.8 ± 12.53). CAD-CAM and shoulder margins showed the least vertical misfit. For horizontal misfit, the maximum was observed in SLM samples with shoulder margin (137.94 ± 37.85) and the least by LWT samples with chamfer (89.38 ± 14.81). Chamfer margins and LWT samples showed the least horizontal misfit among the group samples. Fabrication technique and finish line design play a critical role in reducing the marginal misfit of CoCr copings. Conclusions: For vertical misfit, SLM copings showed poor outcomes compared to CAD-CAM specimens, however comparable outcomes to Cast specimens. SLM copings showed comparable horizontal misfit outcomes to CAD-CAM specimens and low misfit compared to Cast copings, respectively. Vertical misfit was low with shoulder margins, and horizontal misfit was better with chamfer marginal configuration.

Application of the Digital Workflow in Orofacial Orthopedics and Orthodontics: Printed Appliances with Skeletal Anchorage

As digital workflows are gaining popularity, novel treatment options have also arisen in orthodontics. By using selective laser melting (SLM), highly customized 3D-printed appliances can be manufactured and combined with preformed components. When combined with temporary anchorage devices (TADs), the advantages of the two approaches can be merged, which might improve treatment efficacy, versatility, and patient comfort. This article summarizes state-of-the-art technologies and digital workflows to design and install 3D-printed skeletally anchored orthodontic appliances. The advantages and disadvantages of digital workflows are critically discussed, and examples for the clinical application of mini-implant and mini-plate borne appliances are demonstrated.

[Metal 3D printing in dentistry]

The article describes the use of 3D printing in dentistry, the principle of operation of 3D printers for metals, a review of comparative data on the quality and accuracy of the final product of 3D metal printing is carried out. Possibilities and prospects of using 3D metal printing in dentistry are indicated.

Effect of different tooth preparation designs on the marginal and internal fit discrepancies of cobalt-chromium crowns produced by computer-aided designing and selective laser melting processes

PURPOSE

To evaluate the impact of five different tooth preparation designs on the marginal and internal fit discrepancies of cobalt-chromium (CoCr) crowns produced by computer-aided designing (CAD) and selective laser melting (SLM) processes.

MATERIALS AND METHODS

Five preparation data were constructed, after which design crowns were obtained. Actual crowns were fabricated using an SLM process. After the data of actual crowns were obtained with structural light scanning, intaglio surfaces of the design crown and actual crown were virtually superimposed on the preparation. The fit-discrepancies were displayed with colors, while the root means square was calculated and analyzed with one-way analysis of variance (ANOVA), Tukey's test or Kruskal-Wallis test (α =.05).

RESULTS

The marginal or internal color-coded images in the five design groups were not identical. The shoulder-lip and sharp line angle groups in the CAD or SLM process had larger marginal or internal fit discrepancies compared to other groups (P < .05). In the CAD process, the mean marginal and internal fit discrepancies were 10.0 to 24.2 µm and 29.6 to 31.4 µm, respectively. After the CAD and SLM processes, the mean marginal and internal fit discrepancies were 18.4 to 40.9 µm and 39.1 to 47.1 µm, respectively. The SLM process itself resulted in a positive increase of the marginal (6.0 - 16.7 µm) and internal (9.0 - 15.7 µm) fit discrepancies.

CONCLUSION

The CAD and SLM processes affected the fit of CoCr crowns and varied based on the preparation designs. Typically, the shoulder-lip and sharp line angle designs had a more significant effect on crown fit. However, the differences between the design groups were relatively small, especially when compared to fit discrepancies observed clinically.

Effect of different finish line preparations on the marginal and internal adaptation of cobalt-chromium metal alloy copings fabricated by using CAD-CAM technology: A systematic review and meta-analysis

STATEMENT OF PROBLEM

The marginal and internal adaptation of a fixed dental prosthesis depends on a variety of factors, finish line designs being one of them. A clear consensus as to which finish line design can provide a better marginal and internal adaptation with respect to cobalt-chromium metal alloy copings fabricated by using computer-aided design and computer-aided manufacturing (CAD-CAM) technology is lacking.

PURPOSE

The purpose of this systematic review and meta-analysis was to evaluate the effect of different finish line preparations on the marginal and internal adaptation of cobalt-chromium metal alloy copings fabricated by using CAD-CAM technology.

MATERIAL AND METHODS

Electronic (PubMed, Cochrane, EBSCOhost, and Google Scholar) and manual searches were conducted for articles published from January 2010 to December 2020 to identify relevant studies evaluating the effect of different finish line preparations (chamfer, deep chamfer, shoulder, rounded shoulder) on the marginal and internal adaptation of cobalt-chromium metal alloy copings fabricated by using CAD-CAM technology.

RESULTS

A total of 573 articles were obtained via electronic search, and 10 articles were obtained through manual search, of which 24 in vitro studies were selected after title, abstract, and full-text screening and were included for both qualitative and quantitative analyses. The marginal adaptation was evaluated under the parameters of marginal gap, absolute marginal discrepancy, and vertical marginal discrepancy, whereas internal adaptation was evaluated under the parameters of internal gap, cervical discrepancy, axial discrepancy, and occlusal discrepancy. The methods of CAD-CAM fabrication (direct metal laser sintering, hard milling, and soft milling) were considered under the subgroup analysis.

CONCLUSIONS

An overall better marginal and internal adaptation was observed with shoulder and rounded shoulder finish line designs when CAD-CAM methods were used for coping fabrication. Marginal and internal adaptation in chamfer and deep chamfer finish line designs showed better results with soft milling and direct metal laser sintering methods, whereas shoulder finish line showed better results with hard milling.