Personalized Ti6Al4V Implant Abutment Fabricated by Hybrid Laser Powder Bed Fusion Process: Mechanical and Microstructural Perspectives

Patcharapit Promoppatum; Aung Nyein Soe; Maytawee Maneein; Bralee Chayasombat; Phitchayanin Khamlue; Viritpon Srimaneepong; Somchai Urapepon; Du-Hyeong Lee; Pongsakorn Poovarodom

doi:10.1016/j.jmrt.2026.04.162

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Personalized Ti6Al4V Implant Abutment Fabricated by Hybrid Laser Powder Bed Fusion Process: Mechanical and Microstructural Perspectives

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Personalized Ti6Al4V Implant Abutment Fabricated by Hybrid Laser Powder Bed Fusion Process: Mechanical and Microstructural Perspectives

Patcharapit Promoppatum, Aung Nyein Soe, Maytawee Maneein, Bralee Chayasombat, Phitchayanin Khamlue, Viritpon Srimaneepong, Somchai Urapepon, Du-Hyeong Lee and Pongsakorn Poovarodom

Journal of materials research and technology, Vol.42, pp.5223-5233

05/2026

DOI: 10.1016/j.jmrt.2026.04.162

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Abstract

This study investigates the mechanical and microstructural characteristics of customized Ti6Al4V dental abutments fabricated using a hybrid laser powder bed fusion (LPBF) process combined with a machined titanium preform. Customized anterior and posterior abutments were designed and produced. Internal defects were evaluated using high-resolution X-ray micro-computed tomography (micro-CT), while microstructural analysis employed scanning electron microscopy (SEM), electron probe microanalysis (EPMA), and electron backscatter diffraction (EBSD). Hardness distributions were measured across the LPBF region, heat-affected zone (HAZ), and preform substrate. Micro-CT revealed low porosity levels in both geometries, with void fractions of 0.045% in anterior and 0.019% in posterior abutments, and mean pore diameters of 23.2 μm and 25.8 μm, respectively. SEM confirmed a continuous metallurgical bond at the preform interface without visible cracking or delamination, while EBSD identified three distinct zones, which are fine acicular α′ martensite in the LPBF region, transitional HAZ, and equiaxed α+β grains in the preform substrate. EPMA mapping indicated vanadium heterogeneity within the preform substrate and a more homogenized vanadium distribution in the fusion zone. Microhardness testing showed gradient values from 415 HV in the LPBF zone to 360 HV in the preform, with the HAZ averaging approximately 370 HV. The present findings reveal a strong metallurgical bond between the preform substrate and the LPBF region, demonstrating the potential use of the LPBF process for personalized implant abutments.

Additive manufacturing

Customized dental abutment

Laser powder bed fusion process

Microstructural analysis

Ti6Al4V

Details

Title: Subtitle: Personalized Ti6Al4V Implant Abutment Fabricated by Hybrid Laser Powder Bed Fusion Process: Mechanical and Microstructural Perspectives
Creators: Patcharapit Promoppatum - PTT Public Company Limited (Thailand)
Aung Nyein Soe - King Mongkut's University of Technology Thonburi
Maytawee Maneein - PTT Public Company Limited (Thailand)
Bralee Chayasombat - National Science and Technology Development Agency
Phitchayanin Khamlue - National Science and Technology Development Agency
Viritpon Srimaneepong - Chulalongkorn University
Somchai Urapepon - Mahidol University
Du-Hyeong Lee - University of Iowa
Pongsakorn Poovarodom - Medical University of South Carolina
Resource Type: Journal article
Publication Details: Journal of materials research and technology, Vol.42, pp.5223-5233
DOI: 10.1016/j.jmrt.2026.04.162
ISSN: 2238-7854
eISSN: 2214-0697
Publisher: Elsevier B.V
Grant note: King Mongkut's University of Technology Thonburi: KMUTT Partnering Initiative Grant: 2024
This research project was supported by King Mongkut's University of Technology Thonburi: KMUTT Partnering Initiative Grant fiscal year 2024 under the project titled, Manufacturability and surface topography of 3d-printed dental implants. Authors acknowledge NSTDA Charac-terization and Testing Service Center (NCTC) for their support on EPMA and EBSD analysis.
Language: English
Electronic publication date: 04/2026
Date published: 05/2026
Academic Unit: Prosthodontics
Record Identifier: 9985156523902771

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