Selective laser sintering (SLS) is being developed for dental applications. This study aimed to investigate the properties of Ti-6Al-4V and pure titanium specimens fabricated using the SLS process and compare them with casting specimens. Besides, the effect of the building direction on the properties of the SLS specimens was also investigated. Specimens were prepared by SLS using Ti-6Al-4V powder or pure titanium powder. Casting specimens were also prepared using Ti-6Al-4V alloys and pure titanium. The mechanical properties (tensile strength and elongation), physical properties (surface roughness, contact angle, and Vickers hardness); corrosion resistors (color difference and corrosion), and surface properties (chemical composition and surface observation) were examined. Both Ti-6Al-4V and pure titanium specimens produced using the SLS process had comparable or superior properties compared with casting specimens. In comparing the building directions, specimens fabricated horizontally to the printing platform showed the greatest tensile strength, and the surface roughness scanned in the horizontal direction to the platform showed the smallest. However, there was no significant effect on other properties. Thus, the SLS process with Ti-6Al-4V powder and pure titanium powder has great performance for the fabrication of dental prosthesis, and there is a possibility for it to take the place of conventional methods.

For evaluating the impact strength of dental materials, the Izod test or Charpy test has been used, but specimen preparation for these tests is difficult due to the adjustment of a notch on them. By contrast, a weight-drop impact test does not require notched specimens. Therefore, it might be possible to measure the impact strength more accurately than conventional methods. This study aimed to establish appropriate conditions for applying the weight-drop impact test on small specimens of acrylic resin. To determine the most reliable impact fracture energy of acrylic resins, different diameters and thicknesses of PMMA resin specimens, diameters and weights of the striker, and diameters of the supporting jig were compared. For all specimen thicknesses, when the striker diameter was 6–10 mm, the impact fracture energy was constant when the inner diameter of the specimen-supporting jig was 8–10 mm. In addition, the measured E_50% value was mostly equal to the median value of the impact fracture energy. Thus, for the weight-drop impact test, this method was effective for material testing of small specimens, by clearly specifying the test conditions, such as the thickness of disc-shaped specimens, the diameter of the striker, and the inner diameter of the specimen-supporting jig.

Selective laser melting (SLM) and electron beam melting (EBM) enable the fabrication of commercially pure titanium, but the effects of the fabrication method and build orientation on surface characteristics and bonding remain unclear. This study evaluated the surface roughness, wettability, and shear bond strength of titanium fabricated by SLM and EBM at build orientations of 0°, 45°, and 90°, with titanium ingots intended for dental casting serving as reference specimens. The surfaces were wet-ground, air-abraded with 50 µm alumina particles, and treated with a 10-methacryloyloxydecyl dihydrogen phosphate-containing metal primer. Surface roughness (Sa), static water contact angles before and after primer application, and shear bond strength to a resin luting agent after 24 h of water storage were evaluated (n = 15/group). The EBM specimens fabricated at 90° exhibited significantly greater Sa values than the other groups (p < 0.05). Primer application significantly increased the water contact angle in all groups (p < 0.05), although group-dependent differences were observed. No significant differences in shear bond strength were detected among the fabrication conditions (p > 0.05). Thus, under the tested surface treatment conditions, differences in surface roughness and wettability were not accompanied by corresponding differences in the initial bond strength of commercially pure titanium.