Procedure for design and production of implant-based frameworks for complex dental prostheses

A method for the production of a dental prosthetic framework, which comprises at least two fitting structures for the installation of the framework on supporting implants and which is made of a biocompatible material having a density higher than 97%, wherein each of the fitting structures is placed at the position of the implant, wherein the framework is directly produced using a layer-wise selective laser powder processing (SLPP) technique, the method comprising the steps of:

• determining an empirically optimal angle to minimize errors related to layer-wise production;
• positioning the framework under a tilt angle so that a slope of at least one fitting plane of the at least two fitting structures forms an angle in a build volume with a plane having the empirically optimal angle, wherein the framework is positioned so that if possible all of the angles of the fitting planes differ less than 10° from the empirically optimal angle;
• when at least one of the fitting planes has a slope having an angle in the build volume differing more than 10° from the empirically determined optimal angle, designing and producing the respective at least one of the fitting structures to include extra material extending the respective at least one of the fitting structures, wherein the height of this extra material is bigger than a gap size due to a stair effect;
• and
• subjecting said fitting structures including said extra material to a post processing step during which said extra material is removed by a tool to obtain a final framework shape which is free of the stair effect.