This study evaluated, in vitro, the effectiveness of diamond and carbide burs, and bur sequences to remove the plasma-sprayed titanium coating from IMZ fixture surfaces. Fifteen polishing procedures were tested. They included the use of 12, 16, 30 bladed carbide burs or bevered carbide burs and 30, 15, 8 microns mean-particles-size diamond burs. The treated surfaces were evaluated with profilometer and SEM. Worn burs and titanium debris produced by the grinding were observed with SEM. All procedures produce smoother surfaces than baseline plasma-sprayed surfaces for both Ra and Rz(DIN) parameters (P < 0.001). A roughening effect of the 8 microns mean-grit diamond bur and 30 bladed burs were noted. The single carbide burs produce polished surfaces affected by waviness. Waviness was minimized by sequence or diamond bur use. The carbide bur blades were variously damaged after their use. In contrast, the grit of diamond burs was observed to be clogged by titanium debris whose amount seemed to be inversely related to the diamond mean particle size. Debris produced by diamond burs was granular whereas that produced by carbide bladed burs showed needle or flake morphology. In conclusion, the most effective titanium plasma sprayed removal were obtained by 30 microns and 15 microns mean-particle-size diamond burs, i.e. 30 microns plus 15 microns diamond burs and carbide 12 plus 16 bladed burs used in sequence.