Two Million Cycle Fatigue Performance of Custom and Stock Conical-Hex Abutments: A Removal Torque and SEM Study


Selvi F., Bilgen B., Karataş M., Balık A.

CLINICAL IMPLANT DENTISTRY AND RELATED RESEARCH, cilt.27, sa.5, 2025 (SCI-Expanded, Scopus) identifier identifier identifier

Özet

Introduction: Screw loosening remains a frequent mechanical complication in implant-supported prostheses, primarily caused by the gradual loss of abutment-screw preload. The aim of this study was to evaluate the mechanical performance of CAD-CAM custom and stock abutments by measuring removal torque values (RTV) at multiple time points and assessing surface morphology by scanning electron microscopy (SEM), following prolonged loading up to 2 x 10(6) cycles. Methods: Forty-four implant-abutment assemblies with an internal conical-hex connection were divided into two groups: Stock abutments (SA) and custom abutments (CA). After initial tightening, baseline RTVs were recorded. The samples underwent cyclic loading following ISO-14801 standards. RTVs were measured after 50 000, 1 x 10(6), 1.5 x 10(6) and 2 x 10(6) cycles and after post-fatigue re-tightening. SEM analysis was performed at baseline, after 1 x 10(6) and 2 x 10(6) cycles. Results: Baseline RTVs were higher in SA than CA. Both groups exhibited a progressive decrease in RTVs until 1 x 10(6) cycles, with significantly lower values in the CA. Thereafter, a partial recovery was observed up to 2 x 10(6) cycles, with no significant difference between groups. SEM images revealed more extensive surface wear in the SA group, while the CA group demonstrated localized adaptations; however, thread integrity was maintained in all samples. Conclusion: Custom abutments showed lower baseline removal-torque values yet maintained preload as effectively as stock abutments after two-million cycles, confirming the mechanical suitability of both designs for functional loading. The greatest preload loss occurred between 50 000 and 1 x 10(6) cycles; therefore, retightening the abutment screws during the early post-insertion period is recommended to maintain preload stability.