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Contents lists available at ScienceDirect

Journal of Prosthodontic Research

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Original article

Finite-element analysis and optimization of the mechanical properties

of polyetheretherketone (PEEK) clasps for removable partial dentures
Tzu-Yu Penga , Yuki Ogawab , Hiroyuki Akebonoc, Shogo Iwagurod , Atsushi Sugetac ,
Saiji Shimoea,*
a
Department of Anatomy and Functional Restorations, Integrated Health Sciences, Hiroshima University Graduate School of Biomedical and Health Sciences,
Hiroshima, Japan
b
Polymer Matrix Hybrid Composite Materials Group, Research Center for Structural Materials, National Institute for Materials Science, Ibaraki, Japan
c
Department of Mechanical Science and Engineering, Hiroshima University Graduate School of Engineering, Higashi-Hiroshima, Japan
d
Division of Dental Technician, Department of Clinical Practice and Support, Hiroshima University Hospital, Hiroshima, Japan

A R T I C L E I N F O A B S T R A C T

Article history: Purpose: Polyetheretherketone (PEEK), a high-strength, aesthetic, and non-allergic thermoplastic
Received 9 April 2019 polymer, recently became a candidate for replacing metallic components in dental prosthesis. However,
Received in revised form 17 July 2019 as PEEK is flexible, the need for retention presents a key challenge in terms of its clinical application. In
Accepted 26 July 2019
this study, clasps prepared using PEEK were optimized and evaluated to provide the mechanical
Available online xxx
properties required by dentures.
Methods: Seventy-two three-dimensional rod-shape models, based on four thickness/width ratios, three
Keywords:
base widths, and six taper ratios were created. These models were analyzed using finite-element
Polyetheretherketone
Dental clasp
methods to determine which modified clasp arm shape provided the most appropriate mechanical
Shape optimization properties. Three shape-optimized PEEK specimens and one standard-shape Co–Cr alloy specimen were
Fatigue then fabricated. Constant-displacement fatigue testing was performed to calculate load values and
CAD/CAM deformations after ten years of clinical use.
Results: Shape optimization indicated a maximum stress concentration that was consistently located at
the base of the specimen, a correlation between mean load values and thickness that was greater than
that with the width, and a correlation between taper ratio and mean load values. Fatigue testing showed
that although PEEK exhibited significantly lower average load values than the Co–Cr alloy, these were
sufficient for clinical use. All specimens exhibited significant deformation during the first period of
cycling; however, there was no significant difference in the deformation between the two materials after
fatigue testing.
Conclusions: PEEK exerts fewer stresses on abutments compared to standard-alloy clasps, provides
adequate retention, and satisfy aesthetic demands, indicating that PEEK presents a promising alternative
to conventional metal clasps.
© 2019 Japan Prosthodontic Society. Published by Elsevier Ltd. All rights reserved.

1. Introduction have been the source of tremendous changes in the field of

dentistry during the past few decades [1,2].
The development of computer technology ensures the Metal alloys remain the materials of choice for removable
indispensability and popularity of computer-aided design and partial denture (RPD) frameworks; however, these materials are
manufacturing in the field of restorative dentistry, while develop- not aesthetically pleasing because of their metallic color, they carry
ments in digital processing mean that materials that were difficult a risk of causing allergic reactions, and their processing is both
to process are now easily available for manufacture. These factors difficult and time consuming. This has led to an increasing trend in
which patients request metal-free restorations [3,4]. To achieve
completely metal-free restorations, either fiber-reinforced
composites or thermoplastic resin retentive elements are used
* Corresponding author at: Department of Anatomy and Functional Restorations,
to replace metal components. However, the long-term durability of
Integrated Health Sciences, Hiroshima University Graduate School of Biomedical
and Health Sciences, 2-3 Kasumi 1-chome, Minami-ku, Hiroshima 734-8553, Japan. these alternative materials is controversial [5–7]. Moreover,
E-mail address: shimoe@[Link] (S. Shimoe). various types of high-strength zirconia-based ceramics materials,

[Link]
1883-1958/ © 2019 Japan Prosthodontic Society. Published by Elsevier Ltd. All rights reserved.

Please cite this article in press as: T.-Y. Peng, et al., Finite-element analysis and optimization of the mechanical properties of
polyetheretherketone (PEEK) clasps for removable partial dentures, J Prosthodont Res (2019), [Link]
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Fig. 1. Schematic illustration of (A) the specimens and (B) the constant displacement fatigue test.
Fixed area = portion for fixation to the machine, loading point = the loading location used by the testing machine, Wb = width of the base, Wt = tip width, Tb = thickness of the
base, and Tt = tip thickness (all in mm).

such as yttria-stabilized tetragonal zirconia polycrystal (Y-TZP) and cross-sectional area was defined using six taper ratios, as shown in
ceria-stabilized zirconia/alumina nanocomposite (Ce-TZP/A), have Table 1. Overall, a total of 72 differently shaped 3D models were
been recently developed and applied within mainstream restor- created.
ative dentistry. Although the application of zirconia ceramics to
RPD clasps has recently been attempted, their clinical lifespan 2.2. Shape optimization
must still be evaluated [7,8].
Developments in materials science have led to the introduction Shape optimization was performed using the finite element
of polyetheretherketone (PEEK), a high-performance thermoplas- method (FEM). Load values for various clasp arm shapes at
tic polymer, to restorative dentistry, as a candidate for replacing displacements of 0.25 mm and 0.50 mm were measured, and stress
metallic components in dental prosthesis. The mechanical distributions were calculated under each loading condition. The
properties of PEEK do not change during the sterilization process material used for optimization in the present study was assumed
and its elastic modulus is similar to those of human bone, enamel, to be linearly elastic, homogeneous, and isotropic, so as to
and dentin, suggesting it to be a suitable restorative material. PEEK approximate the real properties of PEEK (VESTAKEEP DC4450 R
features stable chemical properties, and is biocompatible, wear- (Lot No.: 57781699), Evonik Japan Co., Tokyo, Japan). The following
resistant, stable at high temperatures, insoluble in water. This data were used, as supplied by manufacturers: tensile strength
material also presents low reactivity with other materials, is non- stress at yield = 110 MPa; modulus of elasticity = 4.8 GPa; specific
allergic, and has lower plaque affinity than other materials such as gravity = 1.52 g/cm3; linear thermal expansion = 0.45  10 4 K 1,
metals and resins. Furthermore, PEEK can be processed using and each model was assembled using linear FEM (Autodesk
computer-aided design and computer-aided manufacturing (CAD/ Nastran In-CAD, AutoDesk Inc., San Rafael, CA, USA). A finer mesh
CAM), rendering it easily reproducible in the event of failure, and was generated at the material interface to ensure the accuracy of
easily relined in the case of resorption [9–16]. force transfer, and all nodes in fixed area were restrained. A
The combination of these unique mechanical and physical concentrated load was applied to the loading points of the models.
properties renders PEEK a promising material for replacing metal Clasp arm shapes with tapered uniformly from the tip to the base
frameworks. To date, there have been few clinical studies that discuss and thinner in width or thickness exhibited better functionality
the application of PEEK as a framework material for RPDs [17,18]; and lower abnormal sensation [22]. Due to this, the appropriately
nevertheless, according to its superior flexible properties, obtaining three shape-optimal 3D models with the required mechanical and
the necessary retentive force and fatigue resistance will be key aesthetic properties could be extracted and fabricated into test-
challenges in the development of PEEK RPD clasps [19,20]. Therefore, specimens.
the objective of this study is to optimize PEEK clasp design in order to
provide the mechanical properties required by RPDs. 2.3. Test-specimen fabrication

2. Materials and methods Three PEEK (VESTAKEEP DC4450 R (Lot No.: 57781699), Evonik
Japan Co) test specimens were fabricated for the shape-optimized
2.1. Generating three-dimensional models 3D models using CORiTEC 250I/DRY (imes-icore, Eiterfeld,
Germany). One standard-shape (base thickness/width of 1.00/
Three-dimensional (3D) models with clasp arms in the form of a 2.00 mm (Group A1), taper ratio of 0.8) cobalt–chromium (Co–Cr)
rod-shape were designed by SolidWorks 2013 (Dassault Systèmes alloy specimen (Co 63%; Cr 30%; Mo 5%; Wironit Extra-hard, Bego,
SolidWorks, Waltham, MA, USA). The 3D models were 15 mm in Bremen, Germany) was also prepared for comparison, and the
length and the loading point was set at 3 mm from the tip (Fig. 1). plastic pattern (SHERAprint-vast, SHERA Werkstoff-Technologie,
These models were classified into four groups based on thickness/ Lemförde, Germany) for the cast was created using Rapid Shape
width ratios (Tb/Wb), and each group was then divided into three D30 II (Rapid Shape, Heimsheim, Germany), then invested and cast
subgroups according to the base width. In each subgroup, the according to the manufacturer’s instructions.

Please cite this article in press as: T.-Y. Peng, et al., Finite-element analysis and optimization of the mechanical properties of
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Table 1. 3D models with 72 different shapes (4 groups, 3 subgroups, and 6 taper ratios for each subgroup).

Groupa Subgroupb Base (mm) Tip (mm)

Wb Tb 0.5-taperc 0.6-taperc 0.7-taperc 0.8-taperc 0.9-taperc 1.0-taperc

Wt Tt Wt Tt Wt Tt Wt Tt Wt Tt Wt Tt
A Group A1 2.00 1.00 1.00 0.50 1.20 0.60 1.40 0.70 1.60 0.80 1.80 0.90 2.00 1.00
Group A2 2.50 1.25 1.25 0.63 1.50 0.75 1.75 0.88 2.00 1.00 2.25 1.13 2.50 1.25
Group A3 3.00 1.50 1.50 0.75 1.80 0.90 2.10 1.05 2.40 1.20 2.70 1.35 3.00 1.50

B Group B1 2.00 1.25 1.00 0.63 1.20 0.75 1.40 0.88 1.60 1.00 1.80 1.13 2.00 1.25
Group B2 2.50 1.56 1.25 0.78 1.50 0.94 1.75 1.09 2.00 1.25 2.25 1.41 2.50 1.56
Group B3 3.00 1.88 1.50 0.94 1.80 1.13 2.10 1.31 2.40 1.50 2.70 1.69 3.00 1.88

C Group C1 2.00 1.50 1.00 0.75 1.20 0.90 1.40 1.05 1.60 1.20 1.80 1.35 2.00 1.50
Group C2 2.50 1.88 1.25 0.94 1.50 1.13 1.75 1.31 2.00 1.50 2.25 1.69 2.50 1.88
Group C3 3.00 2.25 1.50 1.13 1.80 1.35 2.10 1.58 2.40 1.80 2.70 2.03 3.00 2.25

D Group D1 2.00 1.75 1.00 0.88 1.20 1.05 1.40 1.23 1.60 1.40 1.80 1.58 2.00 1.75
Group D2 2.50 2.19 1.25 1.09 1.50 1.31 1.75 1.53 2.00 1.75 2.25 1.97 2.50 2.19
Group D3 3.00 2.63 1.50 1.31 1.80 1.58 2.10 1.84 2.40 2.10 2.70 2.36 3.00 2.63

Wb = width of the base, Wt = tip width, Tb = thickness of the base, Tt = tip thickness (as Fig. 1).
a
Groups are divided based on the thickness/width (Tb/Wb) ratio (Group A: 0.500; Group B: 0.625; Group C: 0.750; Group D: 0.875). b Subgroups are divided based on the
width of the base (Wb) (Subgroup 1: 2.00 mm; Subgroup 2: 2.50 mm; Subgroup 3: 3.00 mm). c Taper ratios are the ratio of the cross-sectional dimensions at the tip to those of
the base [Wt/Wb = Tt/Tb].

2.4. Constant-displacement fatigue testing (0.5- to 0.7-taper), Group D2 (0.7- to 0.8-taper), and Group D3
(0.5- to 0.6-taper) were greater than the lowest acceptable
Test conditions were maintained at room temperature using a retentive force (1.6 N) of RPDs (Fig. 2), and the maximum stresses
Servopulser testing machine (EHF-FD5KN-4LA, Shimadzu Corp., were less than the yield stress (110 MPa) of the employed PEEK
Kyoto, Japan) and carried out under two conditions: one with a material (Fig. 3). Among those, Group B3 (0.9-taper), Group C3
constant displacement of 0.25 mm for both the PEEK and Co–Cr (0.5-taper), and Group D2 (0.7-taper) were slender and with
alloy specimens, the other at a constant displacement of 0.50 mm uniformly tapered; thus, identified as the appropriately three
for only the PEEK specimens. These constant displacements were modified shape-optimal 3D models.
maintained at the loading point of the specimens with a sinusoidal The von Mises stress analyses indicated that maximum stress
wave frequency of 5 Hz. In this way, the present study may assume concentrations were consistently located at the base of each model
that the clasps were inserted and removed from the abutment with (Fig. 4). For each group, there was a significant difference between
an undercut of 0.25 mm or 0.50 mm. The load values were recorded the maximum stress values with varying both cross-sectional
in order to analyze deformation during testing; the deformation of dimensions and taper ratios (P < 0.05). There was also a strong
the specimens in the direction of the load was observed using a positive correlation between the thickness (r > 0.8) and stress
digital microscope (KH-1300, Hirox Co., Tokyo, Japan) every 3000 concentration (Table 2). Additionally, there was a significant
cycles. A total of 15,000 cycles were performed, representing the difference in the mean load values that were obtained for different
simulated insertion and removal of the RPDs over ten years, with cross-sectional dimensions (P < 0.05), and the correlation between
the assumption that the patient would perform four complete mean load values and thickness (r > 0.9) was greater than that
cycles per day. between the mean load values and the width (r > 0.6) (Table 2). For
identical dimensions, a larger taper ratio was associated with
2.5. Statistical analysis increased mean load values (Fig. 2).

The results of shape optimization were recorded, and the 3.2. Constant-displacement fatigue tests
correlation between the cross-sectional dimensions, taper ratio,
load values, and maximum stress were obtained via Pearson Three 3D models (Group B3 (0.9-taper), Group C3 (0.5-taper),
correlation and linear regression. The mean interval load values and Group D2 (0.7-taper)) were selected via shape optimization
and deformations were calculated for the constant displacement and used in the fabrication of PEEK specimens. The Shapiro–Wilk
fatigue tests, and the normality of the distribution and the test and the Levene’s test run on all variables showed normally
homogeneity of variance were primarily analyzed using the distributed and homoscedasticity. Table 3 shows the average load
Shapiro–Wilk test and Levene’s test. Data comparisons were values and deformation in the direction of the loads for PEEK and
conducted using one-way analysis of variance (ANOVA) with the Co–Cr alloy. The Co–Cr alloy (mean: 8.26 N) exhibited
post-hoc Scheffé tests. All statistical analyses were performed consistently and significantly higher average load values than
using IBM SPSS statistical software (SPSS version 24; IBM Corp., PEEK (mean: 2.06–3.67 N) during 15,000 cycles (P < 0.05).
Armonk, NY, USA), and the level of statistical significance was set The deformations in the direction of the loads in all the interval
at 5%. cycles are presented in Fig. 5. All specimens exhibited significantly
greater deformation during the first period of cycling (P < 0.05),
3. Result which then remained unchanged until the end of cyclic testing. The
final extent of deformation after 15,000 cycles was small, showing
3.1. Shape optimization no significant differences between each cycle interval. There were
no significant differences between the deformation of the PEEK
When the displacement was set at either 0.25- or 0.50-mm, (mean: 0.011–0.017 mm) and Co–Cr alloy (mean: 0.017 mm)
the mean load values for Group B3 (0.9-taper), Group C3 samples after 15,000 cycles (P = 0.11) (Table 3).

Please cite this article in press as: T.-Y. Peng, et al., Finite-element analysis and optimization of the mechanical properties of
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Fig. 2. Load values when constant displacements of (A) 0.25 mm and (B) 0.50 mm were applied to the 3D models.
The horizontal dashed line represented the lowest acceptable retentive force (1.6 N) of RPDs.

complex results [21,24,25]. Optimization and simulation are

suitable and time-saving methods for predicting optimal shapes
before fabricating specimens for mechanical testing; and FEM was
selected in the present study as an efficient and flexible method
[26–28]. Fitton et al. [29], suggested that resin clasps need to have a
greater cross-sectional area than a metallic clasp in order to
provide adequate retention, due their relatively high proportional
limit and low flexural modulus. The present study used FEM to
determine the optimized shape of a modified PEEK clasp arm by
adding to the width or thickness of a standard clasp arm (Table 1).
Moreover, tooth shape influences retention by determining the
depth and steepness of undercut available for clasping [24]. Turner
et al. [30] stated that resin clasps require relatively engaged,
deeper undercuts to allow adequate retention, thus the present
study compared the functional differences of clasps with
two undercuts (0.25 and 0.50 mm) by constant-displacement
fatigue testing.
According to the shape optimization results and considering
both comfort and aesthetic aspects, Group B3 (0.9-taper), Group C3
(0.5-taper), and Group D2 (0.7-taper) were provided sufficient
retention (Fig. 2) and not prone to plastic deformation (Fig. 3).
Thus, these three designs were selected for the fabrication of PEEK
Fig. 3. Maximum principal stress of each 3D model when load measured at
constant displacement of 0.50 mm.
testing specimens. Urano et al. [8], tested the maximum principal
When maximum principal stress larger than yield stress (110 MPa, the red dashed stress of Ce-TZP/A clasps using FEM, showing that stresses were
line) means that models prone to plastic deformation; yet, when constant consistently observed at the base of each model, and that stress
displacement of 0.25 mm, the stress values of all models were less than 110 MPa. values decreased with decreasing taper ratio. In the present study,
the maximum principal stress of the PEEK clasps was also
consistently observed at the base (Fig. 4); although in comparison
4. Discussion to Ce-TZP/A clasps, PEEK clasps exhibited lower stress concen-
trations. This difference was due to the fact that ceramic materials
In terms of long-term RPD use, clasp arm design should exhibit lower elasticity and ductility, but higher brittleness. These
minimize stress concentration; however, it has been recognized results imply that the PEEK clasps are less prone to fracture and
that three factors, clasp material, clasp form, and the amount of deformation.
undercut, affect the design of a clasp arm [21]. Materials used in After repeated loading of the polymer materials, low-cycle
RPD construction should exhibit flexibility for use as clasps, but fatigue caused cyclic softening and continuously reduced defor-
rigidity for the other components [22]. Due to its low elastic mation resistance, leading to a gradual increase in the strain [31].
modulus, PEEK exhibits superior flexibility but relatively These material performance results indicate that although the
low rigidity compared to conventional Co–Cr alloys (elastic shape optimization (FEM) suggested that the specimens selected
modulus = 3.0–5.5 GPa for PEEK, compared to >200 GPa for in the present study were not prone to plastic deformation (Fig. 3),
Co–Cr alloys) [13,23]; therefore, PEEK clasps should be thicker plastic deformation did occur after the fatigue experiments.
and with a deeper undercut than Co–Cr alloy clasps in order to However, both PEEK clasps (mean = 0.011–0.017 mm) and the
provide clinically acceptable functionality. conventional Co–Cr alloy clasp (mean = 0.017 mm) exhibited only
Clasp shape parameters such as thickness, cross-sectional slight deformation, and there was no significant difference
dimension, and taper affect the retention of RPDs; however, a between the two materials after fatigue testing (P < 0.05) (Table 3
combined variation of these parameters leads to a variety of and Fig. 5).

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Fig. 4. Representative von Mises stresses (MPa) and distributions, obtained when constant displacements of (A) 0.25 mm and (B) 0.50 mm were applied to the 3D models.

Table 2. Pearson’s correlations between variables: width, thickness, and taper ratio.

Von Mises stress values Load values

Width Thickness Taper ratio Width Thickness Taper ratio

* * * * *
Pearson r value 0.61 0.82 0.51 0.64 0.91 0.21
P value >0.001 >0.001 >0.001 >0.001 >0.001 0.080
*
Correlation is significant at the 0.01 level (2-tailed).

Table 3. Pairwise comparison of the load value and deformation of specimens (n = 7).

Displacement Average load value Deformation

during 15,000 cycles after 15,000 cycles

Mean  SD (N) Mean  SD (mm)

a d
Co–Cr alloy 0.25 mm 8.26  0.55 0.017  0.004
b d
PEEK Group B3 (0.9-taper) 0.25 mm 2.15  0.08 0.012  0.005
c d
0.50 mm 3.20  0.32 0.015  0.005
b d
PEEK Group C3 (0.5-taper) 0.25 mm 2.14  0.14 0.011  0.003
c d
0.50 mm 3.67  0.17 0.017  0.010
b d
PEEK Group D2 (0.7-taper) 0.25 mm 2.06  0.09 0.014  0.006
c d
0.50 mm 3.54  0.29 0.015  0.005

SD: Standard deviation. Within the same column, different letters indicate groups that are statistically different (P < 0.05).

Frank et al. [32], suggested that a retention of 2.94–7.35 N was retentive force for a clasp will actually decide on the type and
necessary in the case of a distal extension RPD to protect against number of clasps in the RPD; however, the lowest acceptable
removal during the chewing of food, and Ahmad et al. [33] asserted retentive force for one clasp was determined to be approximately
that the guiding planes would also provide some retentive force 1.6 N [34,35]. The retentive force required for each component, will
(mean retention = 2.41 N). Various studies have discussed the differ considerably with varying RPD design. The obtained
necessary retentive force for RPD clasps, showing that the suitable constant-displacement fatigue test data (Table 3) indicated that

Please cite this article in press as: T.-Y. Peng, et al., Finite-element analysis and optimization of the mechanical properties of
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of PEEK (mean  SD: 2.06  0.09–3.67  0.17), although the PEEK

clasps did provide sufficient retentive force for clinical use.
3. Tests on the Co–Cr alloy and PEEK to simulate a ten-year clinical
use lifespan (15,000 cycles), showed significantly greater
deformation in the earlier cycles than in the later cycles (P
< 0.05), but there was no significant difference in the long-term
deformation of the two materials (P = 0.11).

Conflict of interest

The authors declare no conflict of interest.

Acknowledgements
Fig. 5. Deformation of the specimens for every 3000 cycles, in the direction of
loading. The authors thank Mr. Katsuhiko Sugawara (KS dental,
Yokohama, Japan) for technical assistance with manufacturing
the specimens, and Evonik Japan Co., Ltd. for supplying the free
the average load values of the PEEK clasp (mean: 2.06–3.67 N) were PEEK materials for specimen manufacture in this study.
smaller than those of the Co–Cr alloy (mean: 8.26 N); although,
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Please cite this article in press as: T.-Y. Peng, et al., Finite-element analysis and optimization of the mechanical properties of
polyetheretherketone (PEEK) clasps for removable partial dentures, J Prosthodont Res (2019), [Link]