Effect of build orientation on trueness and adaptation of intaglio surface of maxillary complete denture metal frameworks fabricated by selective laser melting.

Purpose: We aimed to evaluate the trueness and adaptation of the intaglio surfaces of complete denture metal frameworks fabricated using selective laser melting (SLM) with different building orientations (0°, 45°, and 90°).

Methods: Cobalt-chromium maxillary complete denture metal frameworks were fabricated at 0°, 45°, and 90° using SLM. Trueness measurements were conducted using the best-fit alignment method of three-dimensional inspection software, and adaptation was evaluated using the silicone replica technique. Nonparametric Kruskal-Wallis and Bonferroni tests were performed to determine differences among the groups (P = 0.05).

Results: No significant differences were observed in the root mean square (RMS), positive, and negative deviation values between 0° and 45° group (P > 0.05), and the median, first quartile, and third quartile of each were considered clinically acceptable. For the 90° group, the RMS, positive deviation, and negative deviation values were significantly higher than those of the other groups (P < 0.05). The overall adaptation of the 45° group was better than that of the 0° and 90° groups (P < 0.05), whereas the 0° and 90° groups showed no significant difference (P > 0.05).

Conclusions: The trueness and adaptation of the intaglio surface of cobalt-chromium maxillary complete denture metal frameworks were affected by the building orientation through SLM. Considering both trueness and adaptation, 45° is recommended as the most efficient build orientation for clinical applications.