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. 2025 Jul 5;25(1):1106.
doi: 10.1186/s12903-025-06445-w.

Mechanical behavior of hybrid custom implant abutments with various crown materials: a 3D finite element analysis

Pongsakorn Poovarodom  1 , Guilherme Faria Moura  1 , Fabio Antonio Piola Rizzante  1 , Chaiy Rungsiyakull  2 , Jarupol Suriyawanakul  3 , Pimduen Rungsiyakull  4
Affiliations

Mechanical behavior of hybrid custom implant abutments with various crown materials: a 3D finite element analysis

Pongsakorn Poovarodom et al. BMC Oral Health. .

Abstract

Background: Traditional and innovative materials are widely used in dentistry; however, the mechanical behavior of hybrid custom implant abutments, particularly stress distribution in various material combinations, is not fully understood. The study aims to evaluate the mechanical behavior of hybrid custom implant abutments made from various material combinations, including their effects on von Mises stress, maximum and minimum principal stresses, and deformation.

Methods: Two 3-dimensional (3D) models were constructed: a 1.5 mm subcrestal as the test and an equicrestal model as the control. The subcrestal model explored seven materials (Zirconia, Titanium, Lithium Disilicate, Polymer-Infiltrated Ceramic Networks, PEEK, PEEK reinforced with carbon fiber and reinforced with glass fiber) in various abutment and crown combinations. Each model included an implant, titanium base abutment, abutment screw, a custom abutment, a zirconia crown, and bone. A 200 N load was applied, and a Finite Element Analysis (FEA) assessed peak, volume average, and distribution of von Mises stress and principal stress.

Results: The titanium base (Tibase) exhibited the highest peak and volume average von Mises stresses (306-429 MPa), followed by the custom abutment (40-95 MPa) and crown (46-81 MPa). Material changes significantly impacted stress distribution in the Tibase and customized abutments. PICN, Zirconia, Titanium, and Lithium Disilicate abutments showed peak principal stresses between 77 and 85 MPa, while PEEK variants reduced stress in the custom abutment (35-66 MPa) but increased it in the Ti-base (356-405 MPa). PEEK also increased minimum principal stresses in the Ti-base (-400 to -600 MPa).

Conclusions: Abutment materials have a greater impact on stress outcomes compared to crown materials. Abutments with high Young's modulus contribute to increased core system stiffness in hybrid custom abutment complexes. Choosing abutment materials with a high Young's modulus for hybrid custom implant abutments is essential to optimize stress distribution and enhance the stability of the implant system.

Keywords: CAD/CAM; Customized abutments; Finite element analysis; Material properties; Mechanical performance.

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Conflict of interest statement

Declarations. Ethics approval and consent to participate: Not applicable. Consent for publication: Not applicable. Competing interests: The authors declare no competing interests.

Figures

Fig. 1
Fig. 1
A, Full isotropic view of finite element model with loading and boundary condition. B, bucco-lingual cross section view of testing model with components label
Fig. 2
Fig. 2
Bucco-lingual cross section views of A, Control model and B, Subcrestal model. b, buccal side; l, lingual side
Fig. 3
Fig. 3
Buccolingual cross-sectional view of all tested models of von Mises stress distribution in A, Zirconia abutment. B, Titanium abutment.C, Lithium disilicate abutment. D, PICN abutment. E, PEEK-C abutment.F, PEEK-G abutment. G, PEEK abutment. H, Control zirconia abutment. I, Control titanium abutment. Black circles represent the location of maximum von Mises stress in each model. b, buccal side; l, lingual side
Fig. 4
Fig. 4
Buccolingual cross-sectional view of all crown models. (b) buccal side, (l) lingual side, of maximum (upper row) and minimum principal stress (lower row) distribution in: (A, J) Zirconia abutment. (B, K) Titanium abutment. (C, L) Lithium disilicate abutment. (D, M) PICN abutment. (E, N) PEEK-C abutment. (F, O) PEEK-G abutment. (G, P) PEEK abutment. (H, Q) Control zirconia abutment. (I, R) Control titanium abutment. Black circle represents location of peak (in magnitude) maximum and minimum principal stress
Fig. 5
Fig. 5
Buccolingual cross-sectional view of all customized abutment models. (b) buccal side, (l) lingual side, of maximum (upper row) and minimum principal stress (lower row) distribution in: (A, J) Zirconia abutment. (B, K) Titanium abutment. (C, L) Lithium disilicate abutment. (D, M) PICN abutment. (E, N) PEEK-C abutment. (F, O) PEEK-G abutment. (G, P) PEEK abutment. (H, Q) Control zirconia abutment. (I, R) Control titanium abutment. Black circle represents location of peak (in magnitude) maximum and minimum principal stress
Fig. 6
Fig. 6
Buccolingual cross-sectional view of all titanium base abutment (Tibase) models. (b) buccal side, (l) lingual side, of maximum (upper row) and minimum principal stress (lower row) distribution in: (A, J) Zirconia abutment. (B, K) Titanium abutment. (C, L) Lithium disilicate abutment. (D, M) PICN abutment. (E, N) PEEK-C abutment. (F, O) PEEK-G abutment. (G, P) PEEK abutment. (H, Q) Control zirconia abutment. (I, R) Control titanium abutment. Black circle represents location of peak (in magnitude) maximum and minimum principal stress
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