Acronym of the Project
DentaPrint
Title of the Project
Development of Direct Metal Laser Sintering (DMLS) and Electrolyte Plasma Polishing (EPP) for dental CoCrMo implants.
Positioning of the Project
TRL 6 – technology validated in relevant environment
The scientific and technical objectives of the project are:
Development and characterization of CoCrMo powder
• The project will produce high-quality CoCrMo alloy powders through ultrasonic atomization with adjustable chemical composition and controlled particle size distribution.
• It will ensure phase homogeneity and optimize the microstructure to meet the functional requirements of dental implants.
Optimization of DMLS processing for dense implant fabrication
• The project will aim to achieve high-density (≥99.5%) CoCrMo implant structures with fine microstructure through in-house DMLS process parameter development.
• Statistical optimization methods, such as Response Surface Methodology (RSM), will be used to minimize porosity, defects, and anisotropy.
Comparison between DMLS- and cast-produced CoCrMo alloys
• DMLS-manufactured CoCrMo components will be systematically compared with conventionally cast CoCrMo alloys.
• Microstructure, hardness, corrosion and wear resistance, and biocompatibility of both production routes will be evaluated to understand their performance differences and suitability for dental implant applications.
Implementation and refinement of EPP for surface treatment
• An eco-friendly and effective EPP process will be developed to reduce surface roughness (target Ra < 0.2 µm) and eliminate surface particle adhesion.
• The effects of pH, conductivity, polishing time, and current density on surface morphology, material removal, and microstructure will be systematically investigated.
Enhancement of surface bioactivity via secondary modification
• Hydroxyapatite + Ag coatings will be applied using physical vapor deposition (PVD) to improve osseointegration and provide antibacterial properties without compromising surface integrity.
• Biological evaluations including wettability, in vitro corrosion, cytotoxicity, and cell culture studies will be carried out to confirm enhanced biocompatibility.
Integrated process validation through demonstrator production
• Functional dental implant prototypes will be manufactured and tested under simulated in-vitro conditions to validate the complete process chain.
• A comparative analysis will be conducted between untreated and EPP-treated implants regarding microstructure, surface hardness, wear, and corrosion resistance.
Systematic evaluation and process parameter integration
• The project will study the relationships between powder composition, DMLS parameters, and EPP variables to achieve optimal surface quality and mechanical performance.
• Each stage will be carefully controlled to prevent surface defects, ensuring uniform smoothness, high hardness (>360 HV), and corrosion resistance.