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Purpose: The purpose of this report was to describe a new technique to fabricate onepiece, implant-supported titanium frameworks by means of a computer numericcontroiied (CNO miiiing technique, and to compare the fit of these ramevvork with
conventionai cast prostheses. Materials and Methods: The study comprised 20 patients
who were provided with 5 standard Brnemark implants each in the edentuious
mandible. The fit of the first 10 prostheses with CNC-milled frameworks was measured by
means of a 3-dimensional photogrammetric technique. The distortion of the center point
of the framework cylinders was measured in relation to the master cast replicas. These
measurements were compared with 10 randomly selected routine prostheses with cast
frameworks. Results: No significant differences were found between the 2 groups. The
3-dimen5onal distortion of the cylinders in the compieted prostheses ranged from 3 to
80 (jm: no passive framework was observed. More distortion was observed in the
horizontai plane (x and y axes) as compared to the distortion in tbe vertical direction
2 axis). Conciusion: The precision of fit of the first CNC-milied prostbeses presented a
comparable fit to the conventionai cast frameworks, Consequentiy, tbis new technique
couid be a valid option for the routine fabrication of frameworks for implant prostheses.
int] Prosthodont 1999,-12:209-215.
using goid ailoy castings was to provide a more stabieocciusion in metai and to ai iow for porcelain veneering materials.'-- However, in many cases with severe bone rsorption, large amounts of goid aiioy had
to be cast when the occlusion was placed in metai.
These heavy frameworks caused casting problems
and the risk of distortion of the frameworks increased.
To compensate for the casting probiems associated
with the iost-wax casting technique and to improve
precision of the frameworks, premachined goid-aiioy
'Associate Professor and Head, Prosthodontic Division, The
cylinders were introduced on a reguiar basis in the
Brnemark Ciinic, Demat Health Care, Gteborg, Sweden.
'Manager, tmpiant Prosthetic Production, Nobei Biocare,
Brnemark impiant system (Nobel Biocare) at this
Gteborg, Sweden.
time.' The cyiinders were first cast into the frame^Manager, Electronics and Research Support, Nobel Biocare, work,^** but soldering and luting the cylinders to the
Gteborg, Sweden.
metai frame were aiso tried.'-^ To simpiify the implant
Reprint requests: Dr Torsten Jemt. The Brnemark Clinic, Public clinical and iaboratory protocol, further modificaDental Health, Mediciriaregatan 12 C, S-413 90 Gteborg,
tions to use more standardized bar framewori<s cast
Sweden. Fax: + 46(0131 82 73 29.
in semiprecious aiioys have been tested."*
e-maih torsten.iemt@odontologi.gu.se
2, Number 3. 1999
209
Laboratory
Clinic"
1
2
3
Final impression
Jaw recording
Functional and
esthetic assessment
4
5
Reference Group
Ten edentulous patients who were treated witb standard fixed prostbeses with conventional cast frameworks"-'^ were randomly selected to form the control
group. These patients and prostheses have been described in more detail by Jemt and Lie.^^ Fabrication
of the frameworks was performed by two dental laboratories with experience of more tban 1,000 implant
cases eacb during more tban 10 years. All patients received a type III gold-ailoy casting witb standard
gold-alloy cylinders (DCA 072, Nobel Biocarej.The
frameworks were cast in one piece, and after try-in
of the metal frames resin teeth were cured to the
castings.'' Try-in of tbe prostheses was performed as
described below.
Besides the conventional techniques for cast frameworks, other methods to manufacture prostheses for
implant rehabilitation have also been tested. One
such technique is to use prostheses based on carbon/
graphite fiber-reinforced poly (methyl methacrylate)^;
these prostheses have been shown to function well
in clinical foliow-up studies,'' Another noncasting
approach is to use laser-welded titanium frameworks,^'^ These frameworks are based on prefabricated titanium components, and different techniques
have been described for manufacturing the metal
frames.""^' Clinical experience with titanium frameworks has been encouraging, presenting results comparable to those reported for conventional casting
techniques.'*''' The most recent laser-welded prostheses (titanium type 3 frameworks) were manufactured by welding small, prefabricated titanium components fol lowed by manual contouringof the metal
beam by the technician before curing resin teeth to
the framework.'^'"'^ However, a major problem
with this technique is that the manual contouring of
the metal is too time consuming in the laboratory, and
further modifications of the titanium protocol therefore had to be considered.
A completely new protocol for fabricating titanium
frameworks has been developed, in which no laser
welding or prefabricated components are used. The
aims of the present study were to describe this new
technique for fabrication of fixed implant-supported
prostheses in theedentulous aw, to measure the precision of tbe fabricated prostheses to the master cast,
and to compare these measurements with the precision of routine conventional cast frameworks.
Test Graup
The test group comprised the first 10 consecutive
prostheses that were milled from one piece of titanium in a CNC milling machine. These prostheses
were randomly selected from patients that were
treated with fixed implant-supported restorations in
the edentulous mandible at one c l i n i c (The
Brnemark Clinic, GOteborg, Sweden) from January
to June 1997. The frameworks were fabricated by one
manufacturer (Nobel Biocare).
Clinical Procedures
The clinical restorative protocol was the same for the
2 groups (Table 1), basically following a routine 5appointment clinical procedure.^^ After completion,
all prostheses were clinically tested for acceptable fit.
This technique of clinical assessment has been described in more detail elsewhere.^^ In brief, tbe tryin was performed by following a protocol in which
the bridge locking-gold alloy screw was initially
tightened to the first resistance felt with the screwdriver.^^ From this position of the screw not more tban
half a turn of further tightening was accepted until
complete seating of tbe screw was achieved, using a
torque moment of 10 to 15 Ncm. When they were
clinically accepted, a 3-dimensional (3-d) photograph was taken of the master cast and the fit surfaces
of the prostbeses in the 2 groups (Fig 1).
i oi PfOBthodontit
210
leml el al
Fig 1 Photograph of a complete CNC-milled prosthesis framework taken with the oamera equipment described. At least 3 images of the object are given in the same exposure.
Fig 2 (Rtghl) Trial base with final denture tooth arrangement
(top), framework resin pattern (middle), and final CNC-milled titanium framework (bottom). The titanium framework is a milled
copy of the scanned resin pattern in one piece.
Fig 3
Fig 4
2, Number 3, 1999
211
The Internrion.
I of ProahodaritiC5
Fig 5 fLeft; Completed CNC-milled titanium framework. Note that the oylinders are integral parts of tbe framework,
and tbers are no welding joints.
Fig 6 (Right) Completed prosthesis with
CNC-milied titanium framework and resin
teeth.
Table 2 Mean and Standard Deviation (SD) of Distance Between 2 Terminal Implants (Lateral) and Distance
Between Most Distal and Most Anterior Implants (Sagittal)
Lateral arch distance in mm
(x axis)
Group
Mean
SD
Range
Mean
SD
Range
Mean
SD
Range
Reference
CPJC-mitled titanium
30.7
28.9
2.1
3.2
27.2-33.9
24.6-33.1
8.4
7.3
1.0
1.7
7.1-1D.4
3.7-10.0
0.3
0.3
0.03
0.05
0,2-0.3
0.2-0.3
The photographs were placed in an analytic plotter under stereoscopic vision (Leica, Kern) for 3-d
measurements"''' of the prosthesis and master cast
replica cylinder center points (Atlas 2000, Metimur).
Each pair of measurements (master cast-framework)
was superimposed in the computer and analyzed for
optimal fit by means of the least squares method ,^''"'^''
Distortion of the frameworks was measured and reported in relation to the center point of the cylinders,
comparing the difference of x, y, and z positions as
well as the 3-d distortion for each individual cylinder.
The error of this measuring technique has been repotted in more detail elsewhere.^' Measurements f
the individual center points were calculated to a mean
3-d precision of 1 2 |jm in repeated measurements.
were also presented in absolute figures to show the degree of distortion without considering the direction of
the displaced cylinder, ie, left-right (x axis), anteriorposterior (y axis), or up-down (z axis). Wilcoxon's
ranked sum test^^ was used for statistical comparisons
between the 2 prosthesis designs. A P value of > 0.05
was not considered significantly different.
Results
Reference Group
Distortion of individual cylinders showed a wider
range in the horizontal plane (x and y axes) as compared to the vertical direction (z axis) (Table 3). The
range of mean 3-d distortion measured was from 16
to 80 |jm (Tables 3 and 4), with an overall mean 3-d
distortion of 42 pm (standard deviation 15 |jm).
Accordingly, no prosthesis showed a perfect fit.
When considering the direction of displacement,
the mean distortion in the 3 individual axes was on
average insignificant, but the standard deviations of
the means indicated more variation of misfit in the
horizontal plane (x and y axes; Table 4). When analyzing the same measurements as the mean of the
displacement in absolute figures (disregarding direction of distortion), the misfit in the horizontal
plane became more obvious as compared with the
sagittal displacement (2 axis] of the cylinder (Table
5), No pattern of distortion in relation to position of
the implants could be observed (Tables 4 and S).
Arch Form
All prostheses in the 2 groups were supported by 5
implants each, which were provided with standard
abutments. The width of the implant arch'^ was assessed by measuring the distance between the centers of the 2 most distal implants (x axis). The curvature of the arch was determined by measuring the
sagittal distance from a line between the 2 most distal implantstothecenterofthemost anteriorly placed
abutment (y axis). The measurements of the arch
forms of the 2 groups are given in Table 2.
Statistics
Conventional descriptive statistics were used to present
the distortion of the frarTieworks. The measurements
212
Voliimpl2, Number3
Jemt et al
Table 3
Min
Max
Range
Min
Max
Range
xaxis
y axis
-61
-53
-a4
124
118
64
64
-75
-68
-42
3
72
44
34
76
147
zaxis
3-d
63
65
40
80
16
112
76
73
Position
3-d
1
Mean
SD
5
29
1
35
4
7
42
15
9
22
6
15
2
8
26
12
Mean
SD
6
26
4
35
-6
12
41
17
7
29
-11
27
20
40
20
Mean
SD
-16
32
-11
18
1
16
39
19
14
20
23
9
18
38
9
Mean
SD
9
29
3
34
7
20
47
7
-26
31
5
24
-6
13
35
19
Mean
SD
Total
Mean
SD
7
36
9
27
5
9
42
19
-26
34
-9
23
2
8
44
21
0
30
Q
30
0
15
42
15
0
30
0
30
2
17
37
18
2
-am
3
11
Mean error vector ot center peint trom right (position 1) to iett (position 5).
Reference group
Position
3-d
3-d
42
15
18
15
12
10
6
5
26
12
6
11
41
17
25
14
21
21
15
14
40
20
15
16
12
10
39
19
18
13
19
14
14
12
38
9
25
15
28
17
15
13
47
7
22
20
20
12
12
8
35
19
28
23
23
15
8
7
42
19
36
22
18
15
8
4
44
21
25
17
25
17
10
9
42
15
24
18
19
15
11
10
37
18
Mean
SD
24
16
28
19
6
4
Mean
SD
19
17
31
14
Mean
SD
30
18
Mean
SD
Mean
SD
Total
Mean
SD
Mean absolute error vector ot center poinl from nght (position 1 to left (position 5].
: Number 3,1999
213
The distortion of the cast impiant framework has eariier been shown to increase as the curvature of the Impiant arch and the weight of the casting olioy increase."'These inherent variabies for then i.iventionai
iost-wax casting technique are not present lur the CNC
miiiing procedure. This aiiows for better fii of the titanium frameworks in difficult ciinicai cases with many
implants in large, curved impiant arches. Some ciinicians have refrained from using porceiain-fused-tometai impiant prostheses in the severeiy resorbed edentuious jaw because of the cost and fit probiems
associated with conventionai goid aiioy castings. The
CNC miiiing procedure provides a solution to this fit
probiem, as the macbining of the fit surfaces of the
framework is not affected by the totai amount of metal
in the superstructure. Accordingly, CNC-miiied titanium frameworks can also be considered for rehabiiitation with prostheses with porcelain veneers in the
severeiy resorbed edentuious jaw (Fig 7).
The ciinicai performance of fixed impiantsupported prostheses with titanium frameworks has
shown resuits comparabie to those found for conventionai restorations,^'""'"' Few severe probiems
bave been reported by these patients, and none of
these problems has been positively associated with
the metai in tbe superstructure,'^ iHowever, even
though some studies have reported few, if any, fractures of the titanium metal frames,"''^ others have observed a siightiy higher incidence of fractured frameworks for the titanium prostheses,'"* These fractures
have been in reiation to the welding joints. With a
penetration depth of about 0.6 mm in theweid,^''this
area must be considered to be the weak part of the
framework and shouid not be adjusted by grinding
after completion,'^"''' it is reasonabie to assume that
the risi< of fractures of the metai framework wouid be
significantiy reduced by fabricating the metai superstructure from one soiid biock of titanium.
As discussed above, the CNC miiiing procedure
eliminates probiems with distortion caused by conventionai iost-wax casting techniques, tbereby aiiowing for more predictabie manufacturing of the
frameworks to the master casts, ' ' iHowever, the iimitation of this new technique is that the intraoral fit of
the framework wiii never be better than the accuracy
of the master cast."'^'' Since the master cast never presents an exact orientation of the intraorai impiants-^^
it shouid be of interest not only to optimize the fit of
the framework to the master cast, but aiso to further
improve the accuracy and the precision of the registration of intraorai impiant position. Since this CNC
miiiing technique was introduced, it has become possibie to use new digital means for recording impiant
orientation based on numeric impiant position data
from the master cast. Recent exprimentai ciinical
214
leint et a\
studies have measured bone and framework deformations caused by misfit,-^ soft tissue volume adjacent
to implants,-' and oral implant positions^^ by means
of the photogram metric technique used in the present
study. These recent studies indicate a new option for
recording implant positions without using conventional impression procedures.
12.
1 3.
14.
rtorp A, Linden B, |emt T. Ciinical experiences with laserwelded titanium frameworks supported by implants in theedentulous mandible: A 5-year follow-up study. Int J Prosthodont
1999;12:65-72.
15.
Jemt T. Failures and complications in 391 consecutively inserted ilxed prostheses supported by Brnemark implants in the
edentulous iaw: A study of treatment from the time of prosthesis placement to the first annual check-up. in[J Oral Maxillofac
Implants 1991:6:270-276.
16.
17.
Lie A, Jemt T. Photoe'a'^rr'el'ic measurements of implant positions. Description of a technique to determine the fit bet\veen impiants and superstructures. Ciin Orai Implants Res 1994;5:30-36.
18.
19.
20.
Hinskens L, Cogar L, Kotowski R. A new MS-DOS based integrated sofhvare pacl<age for triangulation and data collection for
close range appiications (part B5, commission V). Int Arch
Photogram Remote Sens 1992:29:11-18.
21.
JemtT, Rubenstein JE, Carlsson L, Lang B, Measuring fit at the impiant pnisthodontic interface. ) Prosthet Dent 1995,75314-325.
Acknowledgments
The CNC tramework prostheses used in thi study were fabricated
by Mr Tond |alevi<. Special Product Laboratory, Nobel Biocare
Nonden, Gteborg, Sweden. The studv was supported hy grants
from Nobel Biocare and Mr Sven-Olav lohansson, Metimur,
Gteborg, Sweden.
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215