Cobalt-chromium (Co-Cr) alloy is a widely used base material for dental fixed prostheses. These restorations can be produced through casting technique, subtractive or additive manufacturing technologies. However, limited information is available regarding the influence of manufacturing techniques on the properties of Co-Cr alloy since most studies used different chemical compositions of Co-Cr alloy for different manufacturing methods. This study compares the mechanical properties, metal-ceramic bond strength, and microstructures of specimens produced by casting, milling, and selective laser melting (SLM) from one single Co-Cr alloy composition. The mechanical properties of the alloy were investigated by tensile and Vickers hardness tests, and metal-ceramic bond strength was determined by three-point bending. Scanning electron microscopy (SEM) with backscattered electron (BSE) images and optical microphotographs were used to analyze the surface microstructures. Compared with the casting and milling techniques, SLM Co-Cr alloy specimens indicated enhanced mechanical properties and comparable metal-ceramic bond strength. Besides, the microstructures of the SLM specimens showed finer grains with more second phase particles than the casting and milling specimens. The results of our study indicate that SLM might be superior to traditional techniques for the manufacturing of fixed dental restorations.

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