Polyetheretherketone (PEEK), a high-strength, aesthetic, and non-allergic thermoplastic polymer, recently became a candidate for replacing metallic components in dental prosthesis. However, as PEEK is flexible, the need for retention presents a key challenge in terms of its clinical application. In this study, clasps prepared using PEEK were optimized and evaluated to provide the mechanical properties required by dentures. Seventy-two three-dimensional rod-shape models, based on four thickness/width ratios, three base widths, and six taper ratios were created. These models were analyzed using finite-element methods to determine which modified clasp arm shape provided the most appropriate mechanical properties. Three shape-optimized PEEK specimens and one standard-shape Co-Cr alloy specimen were then fabricated. Constant-displacement fatigue testing was performed to calculate load values and deformations after ten years of clinical use. 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. 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.

Poly(aryl–ether–ketone) materials (PAEKs) are gaining interest in everyday dental practices because of their natural properties. This study aims to analyze the bonding performance of PAEKs to a denture acrylic. Testing materials were pretreated by grinding, sandblasting, and priming prior to polymerization with the denture acrylic. The surface morphologies were observed using a scanning electron microscope and the surface roughness was measured using atomic force microscopy. The shear bond strength (SBS) values were determined after 0 and 2500 thermal cycles. The obtained data were analyzed using a paired samples t-test and Tukey’s honestly significant difference (HSD) test (α = 0.05). The surface characteristics of testing materials after different surface pretreatments showed obvious differences. PAEKs showed lower surface roughness values (0.02–0.03 MPa) than Co-Cr (0.16 MPa) and zirconia (0.22 MPa) after priming and sandblasting treatments (p < 0.05). The SBS values of PAEKs (7.60–8.38 MPa) met the clinical requirements suggested by ISO 10477 (5 MPa). Moreover, PAEKs showed significantly lower SBS reductions (p < 0.05) after thermal cycling fatigue testing compared to Co-Cr and zirconia. Bonding performance is essential for denture materials, and our results demonstrated that PAEKs possess good resistance to thermal cycling fatigue, which is an advantage in clinical applications. The results imply that PAEKs are potential alternative materials for the removable of prosthetic frameworks.

The purpose of this study was to evaluate the influence of air-abrasion and subsequent heat treatment on the shear bond strength of the bond between indirect composites and a zirconia material. Four surface preparations were employed; ground flat, then heated to regenerate the crystal phase (C); air-abraded with alumina for 10 s (S10), for 20 s (S20), and air-abraded for 10 s and heated (H). Disks were primed with Alloy Primer and bonded either with Estenia or with Gradia composite. XRD analysis suggested that the monoclinic zirconia content was increased by air-abrasion, and decreased by heating. The surface roughness of S10, S20 and H disks was similar. Nevertheless, H groups showed lower bond strengths than the S10 and S20 groups both before and after thermal cycling. Although alumina air-abrasion considerably enhanced bonding between zirconia and indirect composites, subsequent heat treatment had a negative effect on the durability of bond strength.

Polyetheretherketone (PEEK) is a highly sought-after thermoplastic due to its exceptional mechanical properties and biocompatibility. However, bonding PEEK to indirect composite resin (ICR) or denture-based resin (DBR) can be challenging. Laser engraving technology has shown potential to improve bonding for other materials; thus, this study aims to evaluate its effectiveness for PEEK. The experiment involved preparing ingot-shaped PEEK samples, which were then categorized into four groups based on the treatment method employed: without treatment, air abrasion, sulfuric acid etching, and laser engraving (LS). Subsequently, the samples were bonded to ICR or DBR, and their shear bond strength (SBS) was tested with or without thermocycling using a universal testing machine. Furthermore, the failure mode was observed, with statistical analyses conducted to compare the results. The grid-like microslit structure of LS group displayed the highest SBS for bonding PEEK to ICR or DBR (P < 0.05). During the bonding of PEEK to ICR, resin residue and penetration into the microslits were frequently observed in the LS group, indicating cohesive failure. However, when PEEK was bonded to DBR, mixture failure was frequently observed without thermocycling. After thermocycling, only the LS group showed cohesive failure, while the majority of specimens exhibited mixture failure. Laser engraving significantly improves the SBS between PEEK and both ICR and DBR. Furthermore, it was observed that resin had penetrated the microslits, indicating that laser engraving has great potential as a surface treatment method.