Microwave sintering, a form of powder metallurgy, and direct metal laser sintering, an additive manufacturing technique, have enhanced the efficiency and sustainability of processing CoCrMoW alloy powder biomaterials used in dental applications. This work examines the microstructural, mechanical, corrosion, and sustainability performance of CoCrMoW dental implants fabricated through two distinct routes. Dental implants fabricated with the direct rapid tooling route exhibited a fully melted, dense microstructure with smooth surfaces and low porosity (3.02%), which enhanced densification, reduced oxidation, and increased crystallinity. On the other hand, dental implants fabricated through the indirect rapid tooling route showed rougher surfaces and higher porosity (38.19%), as well as higher hardness due to the formation of an amorphous phase and oxide dispersion strengthening. Additionally, they exhibited improved corrosion resistance due to the formation of an effective protective oxide film. The direct rapid tooling route demonstrated a significantly lower potential for global warming (0.34 kg CO2 eq) and fewer repercussions on ecosystems, human health, and resource depletion compared to indirect rapid tooling (19.53 kg CO2 eq). This study has demonstrated that the direct rapid tooling approach offers a superior, more efficient, and environmentally responsible route for fabricating CoCrMoW alloy dental implants.
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