Design and structural deformation assessment of three-dimensional printed dental implants by means of finite element analysis

Abstract

Background

The increasing demand for dental implants necessitates the exploration of advanced materials and manufacturing techniques. Three-dimensional (3D) printing has emerged as a viable method for producing custom dental implants, allowing for intricate designs and improved patient-specific fits. This study focuses on the design and structural deformation assessment of 3D-printed dental implants using Finite Element Analysis (FEA). By simulating the mechanical behavior of these implants under realistic loading conditions, we aim to evaluate their performance and predict potential failure points, ultimately enhancing their reliability and longevity in clinical applications.

Objective

The primary objective of this study is to conduct a comprehensive design and structural deformation assessment of three-dimensional (3D) printed dental implants using Finite Element Analysis (FEA). Specifically, the study aims to:

Evaluate stress distribution and deformation patterns in three 3D-printed dental implant designs under simulated physiological loading.

Compare the stiffness, strength, and elastic behavior of PEEK and CFR-PEEK under occlusal forces.

Identify failure points in implants and bone–implant interfaces by analyzing high stress concentrations.

Predict the biomechanical behavior of a novel dental implant by determining its elastic modulus through finite element analysis (FEA).

Methods

Three models 3D were designed to understand stress distribution with different structures using PEEK as biomaterial, with 4 test conditions modeled and compared. An occlusal load was applied (230 N at 90˚ and 30˚) on the implants. Isotropic, linear elastic, and homogeneous were considerate as properties of the components.

Results

Under axial loads, all models stayed within physiological stress limits, while under 30° oblique loading, Model 3 showed the lowest stress, strain, and pressure.

Conclusions

FEA results indicate that 3D-printed dental implants, particularly the optimized Model 3, maintain safe stress levels under axial and oblique loads, supporting their potential for immediate loading. However, due to numerical limitations, experimental validation remains necessary to advance implant designs that optimize bone regeneration and material efficiency.