Mechanical and numerical performance analysis of polyetheretherketone abutments according to manufacturing methods: Comparison of machining and three-dimensional printing

Abstract

This study specifically utilized Ti6Al4V, machined polyetheretherketone (PEEK), and additively manufactured PEEK to evaluate the biomechanical performance of dental implant abutments. Three abutment designs were tested for mechanical strength and stress distribution under physiological loading conditions using finite-element analysis. The findings showed that the maximum stresses in the cancellous bone region were 5.55 MPa for Ti6Al4V, 5.52 MPa for machined PEEK, and 5.50 MPa for three-dimensional-printed PEEK, with only slight variations between the abutment types. None of the designs caused undue stress in the surrounding bone tissue, despite the Ti6Al4V abutment producing somewhat higher stresses because of its increased rigidity. These findings indicate that machining-fabricated PEEK abutments exhibit biomechanical behavior comparable to conventional Ti6Al4V abutments and may serve as a viable alternative in dental implant applications. In contrast, additively manufactured PEEK abutments demonstrated lower mechanical performance, limiting their suitability for clinical use. Overall, this study provides valuable insights into material selection and manufacturing strategies for dental implant abutments.