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A single computer-aided design for a personalized second-premolar bracket was manufactured by lost-wax casting and by selective laser melting (SLM) (n\u2009=\u200936 per method). Slot height and inter-wall angle were measured on both the support-facing and non-support surfaces. Static and dynamic friction were evaluated using stainless-steel rectangular wires ligated either with tightly twisted stainless-steel ties or with elastomeric modules. Mean slot height was 480.88\u2009\u00b1\u200973.90\u00a0\u00b5m for casting and 421.47\u2009\u00b1\u200932.03\u00a0\u00b5m for SLM, against a nominal 480\u00a0\u00b5m. Overall height error did not differ between methods (\n                    <jats:italic>P<\/jats:italic>\n                    \u2009=\u20090.673), whereas angle er-ror was greater for SLM (17.76\u2009\u00b1\u200911.29\u00b0) than for casting (9.56\u2009\u00b1\u20098.88\u00b0,\n                    <jats:italic>P<\/jats:italic>\n                    \u2009&lt;\u20090.001). The support-facing wall consistently showed reduced accuracy: in casting, height error in-creased on the support side (\n                    <jats:italic>P<\/jats:italic>\n                    \u2009=\u20090.001); in SLM, both height and angle errors increased on the support side (both\n                    <jats:italic>P<\/jats:italic>\n                    \u2009&lt;\u20090.001). Across conditions, static friction exceeded dynamic friction (all\n                    <jats:italic>P<\/jats:italic>\n                    \u2009&lt;\u20090.001). With steel ligation, friction was higher for casting than SLM (median static 6.00 N vs 4.35 N,\n                    <jats:italic>P<\/jats:italic>\n                    \u2009=\u20090.007; median dynamic 5.03 N vs 3.83 N,\n                    <jats:italic>P<\/jats:italic>\n                    \u2009=\u20090.011). With elastomeric ligation, the ranking reversed, with higher friction for SLM (median static 2.95 N vs 2.05 N,\n                    <jats:italic>P<\/jats:italic>\n                    \u2009&lt;\u20090.001; median dynamic 2.54 N vs 2.03 N,\n                    <jats:italic>P<\/jats:italic>\n                    \u2009=\u20090.003). In this standardized local in vitro model, findings suggest a surface-dependent reduction in accuracy at the support-facing wall and a fabrication-by-ligation interaction that may alter the frictional ranking between steel and elastomeric ligations. Cast brackets showed more consistent full-wire seating, whereas SLM brackets may benefit from calibrated design offsets and targeted finishing to limit undersized or tapered slots; validation beyond this setup is needed.\n                  <\/jats:p>","DOI":"10.1038\/s41598-025-34810-w","type":"journal-article","created":{"date-parts":[[2026,1,6]],"date-time":"2026-01-06T11:55:30Z","timestamp":1767700530000},"update-policy":"https:\/\/doi.org\/10.1007\/springer_crossmark_policy","source":"Crossref","is-referenced-by-count":1,"title":["Slot fidelity and ligation-dependent tribology in personalized brackets made by casting versus selective laser melting: an in vitro study"],"prefix":"10.1038","volume":"16","author":[{"given":"Viet Anh","family":"Nguyen","sequence":"first","affiliation":[],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"Minh Ngoc","family":"Tran","sequence":"additional","affiliation":[],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"Ngo The Minh","family":"Pham","sequence":"additional","affiliation":[],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"Thi Bich Ngoc","family":"Ha","sequence":"additional","affiliation":[],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"Viet","family":"Hoang","sequence":"additional","affiliation":[],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"Thi Quynh Trang","family":"Vuong","sequence":"additional","affiliation":[],"role":[{"vocabulary":"crossref","role":"author"}]}],"member":"297","published-online":{"date-parts":[[2026,1,6]]},"reference":[{"key":"34810_CR1","doi-asserted-by":"publisher","first-page":"1349","DOI":"10.1177\/00220345241271937","volume":"103","author":"F Eggmann","year":"2024","unstructured":"Eggmann, F. & Blatz, M. 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