Home Medicine Patient specific root-analogue dental implants – additive manufacturing and finite element analysis
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Patient specific root-analogue dental implants – additive manufacturing and finite element analysis

  • Johannes Gattinger EMAIL logo , Christian N. Bullemer and Ola L. A. Harrysson
Published/Copyright: September 30, 2016
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Current Directions in Biomedical Engineering
From the journal Current Directions in Biomedical Engineering Volume 2 Issue 1

Abstract

Aim of this study was to prove the possibility of manufacturing patient specific root analogue two-part (implant and abutment) implants by direct metal laser sintering. The two-part implant design enables covered healing of the implant. Therefore, CT-scans of three patients are used for reverse engineering of the implants, abutments and crowns. Patient specific implants are manufactured and measured concerning dimensional accuracy and surface roughness. Impacts of occlusal forces are simulated via FEA and compared to those of standard implants.

Keywords: additive manufacturing; biomechanics; dental implant; direct metal laser sintering (DMLS); 3D-printing; finite element analysis (FEA); patient specific; rapid prototyping; root analogue; stress shielding

1 Introduction

Dental implants are the most integral part of modern dentistry to provide a permanent and effective solution for a wide range of dental complications and diseases. Since the first development of implants for edentulous jaw modern dental implants have been considered a safe and reliable solution for replacing missing teeth [1]. In the last 10 years, the application of digital engineering in implant dentistry has become widespread with the introduction of cone beam computed tomography (CBCT), and progress has been made in the development of computer aided design (CAD) techniques. With the availability of high quality CT scans and the development of segmentation software, reverse engineering of dental implants has become a possible solution. Therefore, patient specific root analogue dental implants can be designed by the segmentation of patients’ CT scans where anatomical features, like a tooth, can be modelled and turned into a computer-generated model to use it for manufacturing. Regarding additive manufacturing methods, direct metal laser sintering can be used to directly turn this model into a patient-specific implant that can achieve a faster and more patient-friendly treatment than the conventional procedure (Figure 1) [2].

Figure 1: Surgical procedures of total tooth replacement. State of the art replacement procedure vs. patient specific procedure.
Figure 1:

Surgical procedures of total tooth replacement. State of the art replacement procedure vs. patient specific procedure.

2 Material and methods

To prove the possibility of patient specific implantation as introduced, CT-scans of 3 patients are evaluated. The Scans are segmented with Mimics® and edited with 3-Matic® (both products of Materialise, Belgium) for FEA simulation and direct metal laser sintering. Models of maxillary bone, implants, abutments and crowns are simulated with finite element analysis (ANSYS®). Implants, abutments and screws are fabricated via direct metal laser sintering (EOSINT M280) from Ti-6Al-4V. The fabricated parts are examined concerning dimensional accuracy by 3D-Scanning (FARO® Edge ScanArm ES) and surface roughness by tactile and optical measurement (Mitutoyo SJ-210 and Hirox KH-7700).

2.1 Geometry

The geometry for the root analogue implants and crowns is extracted from CT-scans with Mimics and 3-Matic as shown in Figure 2. Abutments and screws are designed in SolidWorks. The resulting geometries are exported as STL files for manufacturing by direct metal laser sintering and finite element analysis.

Figure 2: Geometry generation of implant abutment and crown from CT-Scan data.
Figure 2:

Geometry generation of implant abutment and crown from CT-Scan data.

2.2 Material properties

Material properties used for the finite element analysis are summarized in Table 1. Young’s Modulus and Poisson’s Ratio of cortical and cancellous bone are determined in respect to previous FEA studies [3], [4], [5].

Table 1:

Material properties of bone and implant used in finite element analysis.

MaterialYoung’s modulusPoisson’s ratio
Cortical bone13,800 MPa0.26
Cancellous bone345 MPa0.31
Ti-6Al-4V sintered13,8000 MPa0.342
Porcelain (Crown)70,000 MPa0.19

2.3 Boundary conditions

In the structural mechanical FEA simulation the material behavior of all bodies are set to linear elastic, homogenous and isotropic. For the contact between implant and bone complete osseointegration is assumed resulting in a contact without gap. The model is fixed in all degrees of freedom at the intersecting planes of the maxilla. Interfaces between crown, abutment and implant are modeled as bonded contact. The interface between bone and implant is modeled as frictional contact with a friction coefficient of 0.65 between implant and cortical bone and 0.77 between implant and cancellous bone [6], [7]. Two forces of 100 N are applied on the occlusal area. One force (F1) pointing in axial direction and the other (F2) with a buccal-lingual orientation and a tilt angle of 45° as shown in Figure 3 [8], [9]. Principal boundary conditions are summarized in Table 2. FEA simulations are done for different patient specific root analogue implants and standard dental implants on first molars from CT-scans of three patients at University of North Carolina dental school.

Figure 3: Boundary conditions applied in finite element analysis.
Figure 3:

Boundary conditions applied in finite element analysis.

Table 2:

Boundary conditions used in finite element analysis.

Forces and contact regionsForceFriction coefficient
F1 (axial)100 N
F2 (45° buccal-lingual)100 N
Implant – Cortical Bone0.65
Implant – Cancellous Bone0.77
Implant – AbutmentBonded
Abutment – CrownBonded

3 Results

3.1 Finite element analysis (FEA)

Results for total deformation, resulting stresses (van Mises, maximum principal and frictional stresses in the contact region of implant and bone) and the sliding distance in the implant bone interface are evaluated and compared between patient specific implants and standard implants.

3.1.1 Deformation/sliding distance

Figure 4 shows an example for the total deformation of the implant system, maxillary bone, implant, abutment and crown under occlusal loading. In this example the root analogue system shows less deformation than the standard implant version. In Figure 5 the results of the deformation of nine simulations are summarized to compare the results of all calculations done with root analogue and standard implants.

Figure 4: Total deformation of crown, abutment, implant and bone for the first right molar of one patient. Comparison of patient specific implant and standard implant under equal loading conditions.
Figure 4:

Total deformation of crown, abutment, implant and bone for the first right molar of one patient. Comparison of patient specific implant and standard implant under equal loading conditions.

Figure 5: Comparison of total deformation and maximum sliding distance between implant and maxillary bone of the implant system with root analogue and standard implant.
Figure 5:

Comparison of total deformation and maximum sliding distance between implant and maxillary bone of the implant system with root analogue and standard implant.

The sliding distance between implant and bone does not differ in a significant way between root analogue and standard implant but is in the same range of about 5–14 μm.

3.1.2 Stresses

Resulting stresses from occlusal loading are compared in Figure 6. It turned out that stresses are a bit lower with root analogue implants but not statistically significant. However the resulting stresses are at least in a similar range.

Figure 6: Comparison of different stresses resulting through occlusal loading of the implant system with root analogue and standard implant.
Figure 6:

Comparison of different stresses resulting through occlusal loading of the implant system with root analogue and standard implant.

3.2 Additive manufacturing

Modeled root analogue and standard implants (Figure 7) are manufactured through direct metal laser fabrication. Investigation of dimensional accuracy via 3D-Laserscanning showed average deviation between the CAD model and the fabricated implants of 50 μm and a maximum deviation of 90 μm.

Figure 7: Direct metal laser fabricated root analogue implants. A: Patient specific implant for first molar with some left over support structure from direct metal laser sintering. B: Patient specific canine implants with and without support structure.
Figure 7:

Direct metal laser fabricated root analogue implants. A: Patient specific implant for first molar with some left over support structure from direct metal laser sintering. B: Patient specific canine implants with and without support structure.

The arithmetic average of the absolute values of surface roughness Ra of the printed parts turned out to be at about 15 μm.

4 Discussion

Direct metal laser sintering has been proven to be a valid manufacturing method for the production of patient specific dental implants [3], [2], [10]. In this study the possibility of two-part (implant and abutment) root-analogue implantation is proven considering the potential of direct metal laser sintering for the fabrication of the implants and finite element analysis to estimate the expectable deformations, stresses and micro-motions in respect to a standard implant. Despite the small sample of only three patients, the upcoming results from the FEA simulations of the patient specific implants are at least as good as the results for the standard implants. Nevertheless, the measured surface roughness of the manufactured implants might be too high for suitable osseointegration [11], [12]. The dimensional accuracy is marginal, which means that in this cases finishing is necessary to grant the fitting of abutments and screws to the implant. The fitting of the implant to the bone could be problematic because of insufficient resolution of the CT-Scan data.

It is to reflect if it wouldn’t be better to fabricate the root analogue implants by milling than via additive manufacturing, because the geometry is not that complex (e.g. no undercuts) that additive manufacturing would be necessary.

5 Conclusion

Results indicate that it would be possible to manufacture patient specific root analogue two-part implants by reverse engineering and direct metal laser sintering. The two-part implant design allows covered healing of the implant. Insertion of abutment and crown follows just after proper osseointegration of the implant as with standard dental implant systems. Anyhow finishing is to be done because of the insufficient dimensional accuracy and surface quality of the sintered parts.

Author’s Statement

Research funding: The author state no funding involved. Conflict of interest: Authors state no conflict of interest. Material and Methods: Informed consent: Informed consent has been obtained from all individuals included in this study. Ethical approval: The conducted research is not related to either human or animal use.

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Published Online: 2016-9-30
Published in Print: 2016-9-1

©2016 Johannes Gattinger et al., licensee De Gruyter.

This work is licensed under the Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 License.

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https://doi.org/10.1515/cdbme-2016-0025
Keywords for this article
additive manufacturing; biomechanics; dental implant; direct metal laser sintering (DMLS); 3D-printing; finite element analysis (FEA); patient specific; rapid prototyping; root analogue; stress shielding
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  93. EyeGuidance – a computer controlled system to guide eye movements
  94. A framework for feedback-based segmentation of 3D image stacks
  95. Doppler optical coherence tomography as a promising tool for detecting fluid in the human middle ear
  96. 3D Local in vivo Environment (LivE) imaging for single cell protein analysis of bone tissue
  97. Inside-Out access strategy using new trans-vascular catheter approach
  98. US/MRI fusion with new optical tracking and marker approach for interventional procedures inside the MRI suite
  99. Impact of different registration methods in MEG source analysis
  100. 3D segmentation of thyroid ultrasound images using active contours
  101. Designing a compact MRI motion phantom
  102. Cerebral cortex classification by conditional random fields applied to intraoperative thermal imaging
  103. Classification of indirect immunofluorescence images using thresholded local binary count features
  104. Analysis of muscle fatigue conditions using time-frequency images and GLCM features
  105. Numerical evaluation of image parameters of ETR-1
  106. Fabrication of a compliant phantom of the human aortic arch for use in Particle Image Velocimetry (PIV) experimentation
  107. Effect of the number of electrodes on the reconstructed lung shape in electrical impedance tomography
  108. Hardware dependencies of GPU-accelerated beamformer performances for microwave breast cancer detection
  109. Computer assisted assessment of progressing osteoradionecrosis of the jaw for clinical diagnosis and treatment
  110. Evaluation of reconstruction parameters of electrical impedance tomography on aorta detection during saline bolus injection
  111. Evaluation of open-source software for the lung segmentation
  112. Automatic determination of lung features of CF patients in CT scans
  113. Image analysis of self-organized multicellular patterns
  114. Effect of key parameters on synthesis of superparamagnetic nanoparticles (SPIONs)
  115. Radiopacity assessment of neurovascular implants
  116. Development of a desiccant based dielectric for monitoring humidity conditions in miniaturized hermetic implantable packages
  117. Development of an artifact-free aneurysm clip
  118. Enhancing the regeneration of bone defects by alkalizing the peri-implant zone – an in vitro approach
  119. Rapid prototyping of replica knee implants for in vitro testing
  120. Protecting ultra- and hyperhydrophilic implant surfaces in dry state from loss of wettability
  121. Advanced wettability analysis of implant surfaces
  122. Patient-specific hip prostheses designed by surgeons
  123. Plasma treatment on novel carbon fiber reinforced PEEK cages to enhance bioactivity
  124. Wear of a total intervertebral disc prosthesis
  125. Digital health and digital biomarkers – enabling value chains on health data
  126. Usability in the lifecycle of medical software development
  127. Influence of different test gases in a non-destructive 100% quality control system for medical devices
  128. Device development guided by user satisfaction survey on auricular vagus nerve stimulation
  129. Empirical assessment of the time course of innovation in biomedical engineering: first results of a comparative approach
  130. Effect of left atrial hypertrophy on P-wave morphology in a computational model
  131. Simulation of intracardiac electrograms around acute ablation lesions
  132. Parametrization of activation based cardiac electrophysiology models using bidomain model simulations
  133. Assessment of nasal resistance using computational fluid dynamics
  134. Resistance in a non-linear autoregressive model of pulmonary mechanics
  135. Inspiratory and expiratory elastance in a non-linear autoregressive model of pulmonary mechanics
  136. Determination of regional lung function in cystic fibrosis using electrical impedance tomography
  137. Development of parietal bone surrogates for parietal graft lift training
  138. Numerical simulation of mechanically stimulated bone remodelling
  139. Conversion of engineering stresses to Cauchy stresses in tensile and compression tests of thermoplastic polymers
  140. Numerical examinations of simplified spondylodesis models concerning energy absorption in magnetic resonance imaging
  141. Principle study on the signal connection at transabdominal fetal pulse oximetry
  142. Influence of Siluron® insertion on model drug distribution in the simulated vitreous body
  143. Evaluating different approaches to identify a three parameter gas exchange model
  144. Effects of fibrosis on the extracellular potential based on 3D reconstructions from histological sections of heart tissue
  145. From imaging to hemodynamics – how reconstruction kernels influence the blood flow predictions in intracranial aneurysms
  146. Flow optimised design of a novel point-of-care diagnostic device for the detection of disease specific biomarkers
  147. Improved FPGA controlled artificial vascular system for plethysmographic measurements
  148. Minimally spaced electrode positions for multi-functional chest sensors: ECG and respiratory signal estimation
  149. Automated detection of alveolar arches for nasoalveolar molding in cleft lip and palate treatment
  150. Control scheme selection in human-machine- interfaces by analysis of activity signals
  151. Event-based sampling for reducing communication load in realtime human motion analysis by wireless inertial sensor networks
  152. Automatic pairing of inertial sensors to lower limb segments – a plug-and-play approach
  153. Contactless respiratory monitoring system for magnetic resonance imaging applications using a laser range sensor
  154. Interactive monitoring system for visual respiratory biofeedback
  155. Development of a low-cost senor based aid for visually impaired people
  156. Patient assistive system for the shoulder joint
  157. A passive beating heart setup for interventional cardiology training
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