Rapid manufacture of removable partial denture frameworks

Purpose - The aim of this study was to explore the application of rapid manufacturing (RM) to the production of patient specific, custom-fitting removable partial denture (RPD) alloy frameworks. RPDs are metal frameworks designed to retain artificial replacement teeth in the oral cavity. Design/methodology/approach - The study was undertaken by applied case study. An RPD was designed using computer-aided design software according to well-established dental technology design principles, based on a digitally scanned cast produced from an impression of the patient's mouth. The RPD design was then exported as an STL file in preparation for direct manufacture using selective laser melting. Dimensionally accurate frameworks were manufactured in 316L stainless steel and chromium-cobalt alloy. These were assessed for accuracy of fit and function on the patient cast and on the patient in clinic. Findings - This successful case study demonstrates that an RM approach can produce fully functional, precisely fitting RPD frameworks for specific individual patients. Research limitations/implications - The study was based on a single design produced using two materials. Further studies are in progress to show that the results can be achieved on a regular and predictable basis. Practical implications - This study provides some practical guidance for the application described and suggests that similar success may be achieved in related custom-fitting applications. Originality/value - The paper demonstrates the successful application of a novel approach to the design and manufacture of custom-fitting dental devices.