Mechanical Properties of 3D-Printed Titanium Alloy Titanflex® Compared to Conventional Materials for Removable Denture Bases: An Experimental Study

This study investigates the mechanical properties of titanium (Titanflex®) and cobalt-chromium (Co-Cr) alloys for potential use in removable denture bases. Titanium alloys have gained attention due to their biocompatibility and regulatory concerns surrounding Co-Cr, which has been classified as a carcinogenic, mutagenic, and toxic to reproduction (CMR) substance under EU MDR (2017/745). Using selective laser melting (SLM), test specimens of Titanflex® and Co-Cr alloys were 3D-printed at different angles (0°, 45°, 90°) and compared to conventionally cast Co-Cr samples. Tensile testing was conducted to assess modulus of elasticity (E), proof stress (Rp_0.2), ultimate tensile strength (Rm), elongation parameters (Ag, Agt, At), and maximum load (Fm). Results showed that Titanflex® printed at 45° (Ti45) exhibited the highest Rp_0.2, Rm, and Fm, indicating superior strength and plastic resistance. Ti0 displayed the greatest elongation properties, highlighting titanium's ductility. Co-Cr alloys demonstrated higher stiffness but lower ductility. Printing orientation significantly influenced mechanical properties, particularly in 3D-printed samples. Overall, Ti45 presented a balanced profile of strength and flexibility, making it a promising candidate for denture bases, while Co-Cr remains a rigid alternative with established clinical use. Future research should explore long-term performance under functional and biological conditions to guide clinical application.