Fabricating titanium denture base plate by laser rapid forming

Purpose This paper aims to improve the efficiency and the quality of metal dental prostheses, reporting on the first patientfitted titanium (Ti) complete denture base plate fabricated by integrating the technologies of computeraided design and computeraided manufacture (CAD/CAM) and laser rapid forming (LRF). Design/methodology/approach To make a complete Ti denture base plate, the traditional lostwaxcasting technique is commonly used in dentistry. In order to simplify this laborintensive process, a new method combined with LRF was invented. Initially, a maxillary edentulous plaster cast was converted to point cloud data by laser scanning system. Subsequently, point cloud data were reconstructed into a 3D solid digital cast, which is stored in standard triangulation language format. Thereafter the 3D denture base was sliced electronically into a sequence of layers defining the regions of the component and, based on it, the complete Ti denture base plate was built layerbylayer using a laser additive manufacturing technology. Findings After CAD/CAM/LRF process, the Ti denture base plate was designed and successfully fabricated layerbylayer. After the traditional dental finishing techniques, the complete Ti denture base plate was made and assessed by clinician and patient. The clinical evaluation on quality of fit was judged to be acceptable. Originality/value The CAD/CAM/LRF system is a potential candidate to replace the traditional lostwaxcasting technique and provides a new platform for the design and manufacturing of custommade Ti denture plates and other restorations especially for implant substructure and framework of partial removal of denture.