Vertical discrepancy and microleakage of laser-sintered and vacuum-cast implant-supported structures luted with different cement types

Abstract Objectives This study aimed to evaluate the vertical misfit and microleakage of laser-sintered and vacuum-cast cement-retained implant-supported frameworks. Methods Three-unit implant-fixed structures were constructed with: (1) laser-sintered Co–Cr (LS); (2) vacuum-cast Co–Cr (CC); and (3) vacuum-cast Pd–Au (CP). Every framework was luted onto 2 prefabricated abutments under constant seating pressure. Each alloy group was randomly divided into three subgroups ( n  = 10) according to the cement used: (1) Ketac Cem Plus (KC); (2) Panavia F 2.0 (PF); and (3) RelyX Unicem 2 Automix (RXU). After 30 days of water ageing, vertical discrepancy was measured by SEM, and marginal microleakage was scored using a digital microscope. Three-way ANOVA and Student–Newman–Keuls tests were run to investigate the effect of alloy/fabrication technique, FDP retainer, and cement type on vertical misfit. Data for marginal microleakage were analysed with Kruskal–Wallis and Dunn's tests ( α  = 0.05). Results Vertical discrepancy was affected by alloy/manufacturing technique and cement type ( p Conclusions Laser-sintered Co–Cr structures achieved the best fit in the study. Notwithstanding the framework alloy, resin-modified glass-ionomer demonstrated better marginal fit but greater microleakage than did MDP-based and self-adhesive dual-cure resin cements. All groups were within the clinically acceptable misfit range. Clinical significance Laser-sintered Co–Cr may be an alternative to cast base metal and noble alloys to obtain passive-fitting structures. Despite showing higher discrepancies, resin cements displayed lower microleakage than resin-modified glass-ionomer. Further research is necessary to determine whether low microleakage scores may guarantee a suitable seal that could compensate for misfit.