Digital evaluation of laser scanning speed effects on the intaglio surface adaptation of laser-sintered metal frameworks.

STATEMENT OF PROBLEM: Laser sintering has several processing parameters, typically under the control of dental laboratory technicians. Laser scan speed is an important parameter, which has a significant effect on manufacturing time but may also affect the adaptation of restorations. However, limited information is available regarding its impact. PURPOSE: The purpose of this in vitro study was to evaluate the intaglio surface adaptation of laser-sintered cobalt-chromium single-crown frameworks sintered at laser scanning speeds of 1, 3, and 6 m/s. MATERIAL AND METHODS: A master bronze metal die was prepared and scanned by using a laboratory scanner to fabricate the metal frameworks for 4 groups (n=10). In group C, the frameworks were fabricated by using the lost-wax method (control). In group L1, L3, and L6, the frameworks were fabricated by using direct metal laser melting (DMLM) at laser scanning speeds of 1, 3, and 6 m/s. After fabrication, 3 scanning data sets were used to evaluate the intaglio surface adaptation: the master die, the intaglio surface of each metal framework, and each metal framework seated on the master die. The intaglio surface adaptation of the metal frameworks was evaluated by using a metrology software program. The data were statistically analyzed by using a 1-way ANOVA, the Tukey honestly significant difference test, and the Tamhane T2 test (alpha=.05). RESULTS: The highest mean intaglio surface discrepancy value was obtained from group L6, and this was significantly different from the other 3 groups (P<.001). No significant intaglio surface discrepancy differences were found among the other groups. CONCLUSION: The amount of intaglio surface discrepancy increased when the laser scanning speed reached 6 m/s.