Optimization of functional performance of additively manufactured cobalt‑chromium‑molybdenum alloy for dental implant applications

Improper selection of Laser Engineered Net Shaping (LENS) process parameters for the fabrication of cobalt‑chromium‑molybdenum (CoCrMo) alloy may result in poor quality components for dental implant applications. To solve the LENS fabrication challenge, this work utilizes response surface methodology (RSM) to investigate the influence of LENS deposition variables on the microstructural and mechanical performance of the manufactured samples for dental implant applications. Analysis of statistical data demonstrated that microhardness and porosity were both significantly influenced by laser scan speed and powder feed rate, while surface roughness is impacted substantially by laser scan speed and laser power. The analysis of the responses revealed that the optimum factors were at a scan speed of 5.3 mms⁻¹, powder feed rate of 4.748 gmin⁻¹ and laser power of 386.896 W to give surface roughness, porosity, and microhardness responses of 8.7775 μm, 0.06 %, and 387.4286 HV, respectively. The models revealed a strong interaction between the actual experimental data and RSM-predicted responses. The results of this research can serve as a guide for determining suitable LENS input factors for the manufacture of dental implants.