Purpose: This in vitro study investigated the effect of implant geometry and diameter on the rotational load fatigue performance of an implant system with an internal conical connection with microthreads.
Materials and methods: Regular (4.2 mm) and wide-diameter (4.8 mm) Astra Tech EV implants with straight (S) and conical (C) geometries were tested with their corresponding titanium abutments, comprising four test groups: 4.2-mm S (Group 1), 4.2-mm C (Group 2), 4.8-mm S (Group 3), and 4.8-mm C (Group 4). Five samples were included in each group. Customized brass implant holders and abutment holders were machined. A rotational load fatigue machine was used to apply a sinusoidally varying load to the implant-abutment interface at an angle of 45 degrees to produce an effective bending moment of 35 Ncm at a frequency of 14 Hz (air temperature: 20°C). The number of cycles to failure was recorded, with the upper limit set at 5 × 106 cycles. Results were analyzed using ANOVA. Failed samples were examined with a scanning electron microscope to evaluate the mode of failure.
Results: Of the 20 total samples, 2 failed, with Groups 1 and 2 each reporting one failure. Abutment and abutment screw fracture were observed in the failed sample in Group 1, while implant and abutment screw fracture occurred in the failed sample in Group 2. All wide-diameter implants ran beyond the cut-off without failure, but abutment screw loosening was noted in one sample in Group 3. No significant difference was found between implant groups of different geometries and diameters. Damage to the abutments and the implant internal surface were noted in all failed samples.
Conclusions: While no significant differences were found between the test groups, failures were observed only in the regular-diameter group. The abutment and abutment screw fractured deep within the implant, and the implant fractured below the simulated bone level. These modes of failure may pose a significant clinical challenge during retrieval of these components.
Keywords: implant fracture; implant-abutment connection; load fatigue.