Background A novel implant framework design is proposed to improve the mechanical durability of acrylic veneer. Purposes Comparing the mechanical durability of acrylic veneer on implant frameworks fabricated from selective laser melting (SLM) with novel design against conventional computer numeric controlled (CNC) milled frameworks. Materials and Methods Implant titanium frameworks with distal cantilever were fabricated by SLM (n = 10) and CNC milling (n = 10). The CNC frameworks had multiple vertical pins, while the SLM frameworks had 3D metal networks of horizontal beams connected by vertical struts. All the frameworks were veneered with acrylic teeth and resin material and were subjected to a static load‐to‐failure test at the cantilever region. The load‐to‐failure readings and the pattern of prosthesis damage were recorded for each prosthesis. Results The CNC and SLM prostheses failed at statistically similar loads. The acrylic veneer around the CNC frameworks tend to initially crack around the distal implant followed by acrylic chipping. Six SLM prostheses failed at the framework connector on the mesial implant by separation of the screw seat. After reloading these prostheses, they failed by acrylic veneer chipping. The SLM prostheses had significantly less incidence of acrylic flexure and severity of acrylic veneer chipping than CNC prostheses. Conclusions The SLM framework with novel design is efficient in reinforcing acrylic veneering. However, the SLM frameworks appeared weak in thin sections, such as the screw seat.
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