Abstract

This study investigates the effects of post-processing on the surface roughness, wettability, and frictional behavior of selective laser-melted (SLM) cobalt–chromium–tungsten (CoCrW) alloys for orthodontic use. The SLM-CoCrW specimens were tested in as-manufactured, mechanically polished, and electropolished states. Surface characterization via stylus profilometry and atomic force microscopy (AFM) showed that both polishing methods reduced macro- and micro-scale roughness, with electropolishing producing the smoothest, most uniform topography. Static water contact angle (WCA) measurements revealed that mechanical polishing provided an optimal balance of roughness and hydrophilicity, resulting in the lowest friction, while ultrasmooth electropolished surfaces exhibited slightly higher friction due to increased hydrophobicity and a uniform Cr-rich oxide layer confirmed by X-ray photoelectron spectroscopy (XPS). XPS also indicated that electropolishing generated a homogenous chromium oxide passive film, whereas mechanical polishing left a chemically heterogeneous surface with exposed metallic sites. Importantly, performance is not governed solely by surface roughness; surface chemistry is equally critical, and both must be considered together—along with wettability and tribological behavior—to achieve optimal functional outcomes. From a clinical perspective, optimization of surface roughness and surface chemistry may result in decreased frictional resistance, improved sliding mechanics, and enhanced long-term performance of additively manufactured orthodontic components; however, the present study was restricted to in vitro characterization under simplified laboratory conditions, and further investigations involving artificial saliva, long-term aging, wear and clinical simulations are necessary to validate the translational relevance of these findings.

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