Stress analysis of cantilever-fixed partial denture connector design using the finite element method

Purpose: To analyze the stress distribution on a cantilever-fixed partial denture after simulation of maximum mastication loads in order to optimize its design. Methods: A cantilever-fixed partial denture framework was designed in the CAD-CAM system Everest®Kavo v2.0 using two materials, titanium and zirconium, with connectors of 5.28 mm2 and 9.05 mm2, respectively. A finite element model was built for stress analysis using simulations of mastication load. Results: For zirconia, only the molar cantilever with the smaller connector area and a 0.5-mm fillet exceeded the considered threshold resistance value of 575 MPa. All the other designs yielded resistances below this value. For titanium, only cantilevers with 9.05 mm2 connector area and fillets of 1 or 1.4 mm presented stress values inferior to titanium yield strengh. Conclusion: Within the limitations of this study, it can be concluded that titanium cantilever-fixed partial denture frameworks with a 5.28 mm2 connector area cannot support maximum mastication loads; frameworks of this material require larger connectors with fillets introduced in the gingival embrasure. Zirconia, however, supports maximum bite forces in most situations with both molar and premolar design cantilevers. Precaution should be taken when dealing with smaller connectors of 5.28 mm2.