A novel strategy for the production of sintered ceramic dental implants is reported. The innovative and versatile 7-axes laser processing test bench makes the production of complex shapes with high precision possible. Quasitangential strategies prove an average deviation smaller 5 μm with a surface roughness Ra of 0.24 μm. The material is an yttria-stabilized alumina-toughened zirconia ceramic suited for biological applications subjected to load and wear. The heat-affected zone is negligible as shown by Raman spectroscopy. Following, this layer is laser ablated with an orthogonal strategy. Defined surface structures, like spots and grooves in the micrometer regime, are introduced for potential altered tissue interaction and enhanced osseointegration.
A novel conditioning routine of metallic bonded diamond grinding worms is reported. The competitive manufacturing time is realized by a combination of orthogonal and quasi-tangential laser processes. The introduced quasi-tangential process is only limited by the maximum available laser power of 100W at 10 ps and 800 kHz for roughing. Hence, a maximal ablation rate of 55mm3 min-1 is reported and the accumulated ablation rate for conditioning is 3mm3 min-1. Following, the manufacturing of grinding tools within a maximal geometric deviation of 40 μm is shown. The threaded tool is finished by a laser sharpening process exposing the bonded diamonds on the surface for increased cutting characteristics. Thermally induced phase transitions are assessed via Raman spectroscopy and reveal a negligible heat-affected zone.
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