Abstract This study aimed to analyze the wettability characteristics applied to the surface of heat-treated pure titanium grade 2. Titanium is widely used for applications in implants produced by incremental sheet forming (ISF), where the 3D model resulting from tomography was used to produce the part. Since the ISF process creates residual stresses in the sheet, heat treatments were applied to relieve them. Also analyzed were roughness, researching what the literature recommends to enable surface wettability. Tests were conducted to assess geometric discrepancy using 3D scanning. The results obtained prove the efficacy of the experiment in assessing wettability as a characteristic of bioactivity, which is necessary for applications involving the human body. In addition, geometric discrepancy analysis enables the prosthesis to be used with the best esthetic and functional comfort possible.

INTRODUCTION: This work aims to pre-operatively manufacture custom-made low-cost implants and physical models (‘biomodels’) of fractured skulls. The pre-DOI: operative manufacturing of biomodels and implants allows physicians to study and plan surgery with a greater possibility of achieving the expected result. Customization contributes to both the esthetic and functional outcome of the implant because it considers the anatomy of each patient, while the low cost allows a greater number of people to potentially benefit. METHODS: From CT images of a fractured skull, a CAD model of the skull (biomodel) and a restorative implant were constructed digitally. The biomodel was then physically constructed with 3D Printing, and Incremental Sheet Forming (ISF) was used to manufacture the implant from a sheet of pure grade 2 titanium. Before cutting the implant’s final shape from a pre-formed sheet, heat treatment was performed to avoid deformations caused by residual stresses generated during the ISF process. RESULTS: A comparison of the dimensions of the implant and its respective CAD biomodel revealed geometric discrepancies that can affect both functional and aesthetic efficiency. Nevertheless, the final shape preserved symmetry between the right and left sides of the skull. Electron microscopy analysis did not indicate the presence of elements other than pure titanium. CONCLUSION: Dimensional variability can be decreased with changes in the manufacturing process (i.e., forming and cutting) and the heating ramp. Despite biomedical characteristics, there was no contamination of the implant by harmful chemical elements. 3D Printing was effective in making the biomodel, enabling pre-operative planning and improving physician-patient communication. Current results indicate that ISF is a process that can be used to obtain custom-made implants.