Selective Laser Melting (SLM) has fundamentally changed what's possible in dental manufacturing. Where casting once required hours of manual labor and introduced variability at every step, SLM delivers net-shape metal parts directly from a digital file — with tolerances measured in microns. For labs producing partial frameworks, metal crowns, and implant components, that precision translates to better fit, less chairside adjustment, and happier patients.

This guide walks through how SLM works, why titanium and cobalt-chrome are the preferred materials for dental applications, and what a realistic production workflow looks like — from initial file preparation through to a finished, polished prosthetic.

How Selective Laser Melting Works

SLM is a powder bed fusion process. The printer spreads an ultra-thin layer of metal powder — typically 20 to 40 microns thick — across a build platform. A high-power fiber laser then traces the cross-section of the part for that layer, melting the powder particles together into solid metal. The platform drops one layer height, fresh powder is spread, and the process repeats — layer by layer — until the full part is built.

The entire process takes place inside a sealed chamber flooded with inert argon gas. This prevents oxidation of reactive metals like titanium during printing, which is critical for achieving the biocompatibility and mechanical properties required in dental prosthetics.

Key Process Parameters

The quality of an SLM part is determined by four interrelated parameters that must be balanced for each material and geometry:

Modern dental SLM systems like the Space Ti-160 come with validated parameter sets for cobalt-chrome and titanium alloys — so labs don't need to develop their own from scratch. These pre-validated profiles are what separate purpose-built dental printers from general industrial machines.

Why Titanium and Cobalt-Chrome?

The dental industry has converged on two primary metal alloys for prosthetics: Grade 5 titanium (Ti-6Al-4V) and cobalt-chrome-molybdenum (CoCrMo). Both are ISO-certified for dental use and have decades of clinical history. They also happen to be among the best alloys for SLM processing.

Titanium (Ti-6Al-4V)

Titanium is the material of choice for implant-adjacent restorations, bars, and frameworks where biocompatibility is the top priority. It is the most biocompatible metal used in medicine, produces no galvanic reaction with titanium implant bodies, and is approximately 40% lighter than cobalt-chrome — improving patient comfort in full-arch cases.

"Titanium is not just biocompatible — it is osteoinductive. Its oxide layer actively encourages bone integration, which is why it remains the undisputed standard for implant hardware."

— HiZir Technical Team

Cobalt-Chrome (CoCrMo)

Cobalt-chrome offers exceptional hardness and wear resistance, making it the preferred choice for partial denture frameworks, clasps, and any application where thin cross-sections must carry high loads. Its elastic modulus is closer to bone than titanium, and it can be cast thinner — reducing bulk and improving aesthetics in visible areas.

Both Ti-6Al-4V ELI and CoCrMo alloys used in the Space Ti-160 are supplied as pre-alloyed powders with certified composition and particle size distribution, ensuring batch-to-batch consistency that hand-mixed casting alloys can't match.

The Complete Production Workflow

Understanding the full workflow from prescription to delivery is essential for labs evaluating whether to bring SLM in-house. Here's what a typical partial framework job looks like.

  1. Scan & design — Intraoral or model scan captured; partial framework designed in dental CAD software (e.g., exocad, 3Shape)
  2. File preparation & nesting — STL exported, supports added in nesting software, parts oriented to minimize support volume and maximize surface quality on critical surfaces
  3. Printing — Build plate loaded, parameters selected, print initiated; a full Space Ti-160 build plate of partial frameworks typically prints in 3— hours depending on part count and height
  4. Stress-relief annealing — Parts remain on the build plate and go into the Space Ti-200 annealing furnace; thermal cycle relieves residual stress from rapid solidification, improving ductility and fatigue life
  5. Support removal & finishing — Parts separated from build plate using wire EDM or band saw; supports removed manually or with cutters; sandblasting removes loose powder
  6. Plasma polishing — Parts processed in the Plasma Polish Machine; electrochemical surface finishing removes micro-peaks, reduces surface roughness to Ra <0.2 µm, and produces a biocompatible oxide layer
  7. Quality check & delivery — Parts inspected dimensionally and visually; shipped to the prescribing dentist or fitted chairside

SLM vs. Casting: A Practical Comparison

Labs considering SLM often ask how it compares to their existing casting workflow. The answer depends on volume, complexity, and what you're making.

For labs with high frame volume, the economics shift dramatically in favor of SLM within 12–18 months of purchase. For lower-volume labs, the bureau printing model — submitting files and receiving finished parts — provides access to SLM quality without the capital investment.

Getting Started with HiZir

Whether you're evaluating the Space Ti-160 for in-house use or want to submit your first outsourced print job, the HiZir team is available to walk through your specific case mix and calculate a realistic ROI projection. Reach out by email at info@HiZirLab.com or call +1 (314) 403-5175.