Load-bearing capacity of screw-retained fixed dental prostheses made of monolithic zirconia on different abutment designs and abutment-free implant connection

Abstract

Objectives: A new abutment-free implant connection allows for direct screwing of FDPs on implants to avoid complications caused by cement rests or screw loosening, which may affect to screw torque and load distribution. The objective of this study was to test the initial (Fi) and final failure (Ff) loads and torque changes of abutment-free monolithic zirconia CAD-CAM fixed dental prostheses (FDPs) compared to titanium FDPs on different abutment designs.

Methods: Three-unit screw-retained FDPs (n = 50) on two implants (n = 100) were divided into groups (n = 10) based on the implant-abutment connection and material of the supra-structure: (1) abutment-free monolithic CAD-CAM zirconia FDP (Abut-free-Zr), (2) abutment-free veneered titanium FDPs (Abut-free-Ti), (3) monolithic zirconia FDPs with titanium base abutments (Zr-Ti-Base), (4) monolithic zirconia FDPs on multi-unit abutments (Zr-MU), (5) veneered titanium FDP on multi-unit abutments (Ti-MU). All specimens were subjected to thermo-mechanical aging (1'200'000 Cycles, 49 N, 1.67 Hz, 5º to 50º C, dwelling time 120 s). Torque of the screws was measured, and static loading was performed. Data were tested using ANOVA and Tukey's tests (p < 0.05).

Results: After thermo-mechanical aging, all screws showed reduced torque, Ti-MU significantly more reduction compared to Abut-Free-Ti (p = 0.0021). Titanium groups showed significantly lower Fi (N) values (171.4-230 vs 1272-1358,) due to veneering porcelain fractures (p = 0.0001) and significantly higher Ff (N) (2922 -3029 N vs. 1272-1358) values than zirconia groups (p < 0.0001).

Conclusions: Three-unit abutment-free monolithic zirconia FPDs showed similar failure loads compared to other zirconia groups, while the titanium groups exhibited superior final failure loads. Different abutment designs did not seem to affect the failure loads.

Clinical significance: The specific design of the novel implant interface allows for the fabrication of implant supported FDPs with personalized design directly on implant level without abutments. The monolithic zirconia FDPs on abutment-free implant connection can be used with good confidence since they exhibit similar mechanical stability as monolithic zirconia FDPs on titanium-base or multi-unit abutments.

Keywords: CAD-CAM; Dental implants; FDP; Monolithic; Personalized; Prosthodontics; Zirconia.