Background/Purpose: Esthetic coated arch wires are the desired types to match esthetic brackets in the clinical orthodontics, but the presence of coating layer is greatly affect friction during sliding mechanics. The aims of this study were to evaluate the effect of total wire dimension with the type and thickness of coating layer on friction of coated stainless-steel wires. Methods: The sample of this study consisted of 140 segments of coated stainless-steel arch wires involving two wire dimensions (0.016 × 0.022 inch and 0.019 × 0.025 inch). The samples were supplied from seven companies (DB, RMO, TP, DANY, G&H, Highland and Hubit) and the uncoated control samples were supplied from IOS company. Wire dimensions and thickness of coating layer were measured by the metallurgical light incident microscope and the static frictional force was measured using pulling the wire through set of ceramic brackets by the universal testing machine. The data were then statistically analyzed using ANOVA tests. Results: Generally measured wire dimensions do not match the stated dimensions by the manufacturer. The frictional forces of coated wires differ from uncoated control being higher in the labially coated wires and lesser in the fully Teflon coated wires owing to differences in the wire dimension, thickness of coating layer, and physical properties of coating materials. Conclusion: when tested in vitro, Teflon fully coated wires produce the least amount of friction.
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