Casting over Metal Method Used in Manufacturing Hybrid Cobalt-Chromium Dental Prosthetic Frameworks Assembles

Cobalt–chromium (Co–Cr) alloys are the most widely used materials for removable and fixed dental prosthetic frameworks. The fitting accuracy between these components in dental prosthetic frameworks assembles (DPFAs) is largely influenced by the manufacturing method. This study presents a novel manufacturing method that combined two common techniques for obtaining one single framework: casting of Co–Cr inserts on top of parts previously manufactured by selective laser melting (SLM) of Co–Cr powder (CoM). Horizontal (n = 4) and vertical (n = 3) surfaces were microscopically analyzed (n = 770 count sum). The results revealed a high precision of the process and high fitting accuracy between the hybrid frameworks. The average distance measured between the frameworks in joined position was 41.08 ± 7.56 µm. In conclusion, the manufacturing of Co–Cr alloys DPFA using the CoM method reduced the deformation of hybrid frameworks and improved the joining accuracy between them.