Metallic Ion Release Behaviors from Cobalt-Chromium Alloys Fabricated by Additive Manufacturing with Mechanical Grinding in an Acidic Saline Solution.

This study aimed to investigate the release of metallic ions from cobalt-chromium (Co-Cr) alloys fabricated by additive manufacturing (AM) for comparison with dental casting. Co-Cr alloys were fabricated via AM using selective laser melting (SLM) and electron beam melting (EBM) in powder-bed fusion. Polished and mechanically ground specimens were prepared. Each specimen was analyzed using an electron probe microanalyzer (EPMA). Each specimen was immersed in an acidic saline solution for 7 days in accordance with ISO 10271: 2020. The EPMA indicated the segregation of some elements in the as-prepared SLM and EBM specimens, whereas the polished and ground specimens exhibited a homogenous elemental distribution. The total amount of ion release from the SLM and EBM specimens was confirmed to be less than 7 μg/cm2, which was less than 42 μg/cm2 for the cast specimen. The polished and ground specimens exhibited an even lower ion release than the as-prepared specimens. The amount of ions released from the Co-Cr alloy was less than the 200 μg/cm² requirement of ISO 22674: 2022. Co-Cr alloys fabricated by SLM and EBM could provide superior corrosion resistance to cast specimens. AM could be a valuable method for fabricating appliances and denture frameworks in dentistry.