Controversy regarding patient exposure to mercury from dental amalgam is more than 150 years old. Researchers continue to investigate the amount of mercury vapor released from amalgam both in vivo and in vitro. In this investigation, an in vitro testing method previously described in the literature was used to quantify the effect of operator-controlled variables on mercury release from dental amalgam. The variables tested were alloy morphology (spherical, admixed or atomized irregular particle), operator skill (inexperienced, novice and expert), operator technique (overfill and evenly fill) and cavity design (standard Class 1, double volume and double surface area). Preparations fabricated in sections of acrylic rod were filled with dental amalgam, placed in 25 m-L glass bottles and sealed. Mercury vapor concentrations were measured using a Jerome M-411 at specified times. Standardized mean concentrations for each time and total mercury released over time were calculated and analyzed with ANOVA and Tukey HSD. Statistically significant differences (alpha = 0.05) were identified for all variables tested. Total mercury vapor release was consistently found to be greater for admixed as compared to spherical amalgam. Amalgam restorations prepared by an inexperienced operator demonstrated statistically less mercury vapor than a novice or experienced clinician for both spherical and admixed morphologies. A statistically significant difference in mercury vapor using different condensation and carving techniques was found for the spherical amalgam but not for the admixed material. Restoration design demonstrated significant differences in total mercury vapor dependent on volume and exposed surface area of the amalgam restoration. In this in vitro investigation, mercury vapor release from amalgam was dependent on alloy morphology, operator experience, operator technique and restoration design.