Effect of layer thickness on the flexural strength of multiple-unit laser-sintered metal frameworks

Abstract Statement of problem Laser sintering devices have been increasingly used to fabricate the metal frameworks of metal–ceramic restorations. In the fabrication process, the sintering layer thickness is an important parameter; however, information on how it may affect the flexural strength of metal frameworks remains limited. Purpose The purpose of this in vitro study was to evaluate the flexural strength of 3-unit and 4-unit cobalt-chromium (Co-Cr) metal frameworks laser sintered with 20-μm, 30-μm, and 40-μm layer thicknesses. Material and methods Three-unit and 4-unit master metal die models with premolar and molar abutments were prepared through direct metal laser sintering (DMLS). A total of 40 metal frameworks (n=10 for each metal die model) were fabricated by the lost-wax technique (group C, served as the control group) and through DMLS with 20-μm, 30-μm, and 40-μm layer thickness (experimental groups LS20, LS30, and LS40, respectively). Each metal framework was cemented to a master die with a polyvinyl siloxane impression material and then subjected to a 3-point bend test at a crosshead speed of 1 mm/min. The yield force of each metal framework was used to calculate the flexural strength. Data were statistically analyzed by using 1-way ANOVA followed by a Tukey honestly significant difference (HSD) test and an independent-samples t test (α=.05) The microstructure of the fracture surface was evaluated by scanning electron microscopy. Results Group C reported the lowest mean flexural strength (P .05) in flexural strength was observed among the DMLS groups. The 3-unit metal frameworks exhibited a statistically significant higher mean flexural strength than the 4-unit metal frameworks (P Conclusions The sintering layer thickness did not significantly affect the flexural strength of the laser-sintered metal frameworks. However, the DMLS groups reported a higher mean flexural strength than the cast group.