The passive fit of implant-supported prosthesis is critical for a successful treatment. Objectives: The aim of this work was to evaluate the passive fit of fixed implant-supported frameworks fabricated from titanium in one-piece casting or after laser welding procedure, before and after the marginal refinement using the spark erosion. Methods: Twenty patterns were fabricated from a master die containing five parallel titanium fixtures in the inter foramen region and the castings were processed in commercially pure titanium (cp Ti - Rematitan – Dentaurum - Germany). The specimens were divided into two groups (n=10): G1 - one-piece castings and G2 – four- piece castings followed by laser-welding procedure (Desktop Laser – Dentaurum - Germany). The passive fit between the frameworks and the implants were evaluated before and after the spark erosion marginal refinement (Tel-Med Technologies - USA). The measuring protocol was as follow: the titanium screw of the extremity fixture was 10 N tighten and the gaps at the central (CI) and distal implants (DI) were measured using an optical traveling microscope (Olympus STM - Japan). The results were submitted to ANOVA and means with significant differences were analyzed with t-Student and paired t-Student tests. Results: The results (in micrometers) obtained for G1 (CI 170 and DI 472); G1+EDM (CI 56 and DI 154); G2 (CI 65 and DI 155); G2+EDM (CI 28 and DI 59) indicated significant differences among G1 and G1+EDM, G1 and G2, G1 and G2+EDM, G1+EDM and G2+EDM. No statistical differences were noted in G1+EDM and G2. Conclusion: One-piece castings submitted to marginal refinement with spark erosion fits as well as after laser-welded four-piece castings. The passive fit was improved significantly when marginal refinement with spark erosion was associated with laser-welding procedure.

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