Workflow Development of a 3D Printed Novel Implant Abutment

Dental implant components, including titanium abutments and superstructures, are currently fabricated through subtractive manufacturing. This investigation explored an additive manufacturing workflow using titanium for the fabrication of a novel dental implant abutment. The novel abutment was designed, patented, digitally refined, and printed in dental-grade titanium Ti64 (titanium 6-aluminum 4-vanadium) using selective laser melting technology. Numerous iterations of the abutment were designed, printed, and evaluated to determine the final optimized design for additive manufacturing. Postprocessing involved bead blasting, fixation with a custom stabilization jig, and manually creating threads using a die. The coupling of the abutment with the implant body was suitable, as assessed under magnification and through radiological assessment. Physical testing of the abutment has been completed. Data indicate that the component can withstand the recommended torque and strength required for provisionalization. The additive manufacturing pathway for abutment fabrication presents an efficient, cost-effective, and customizable workflow.