Despite the widespread use of titanium implants in orthopedic and dental surgeries, concerns have recently emerged regarding potential deformations and fractures after osseointegration. In a recent clinical case, a titanium implant fractured after successful osseointegration. This fracture occurred despite the absence of any significant trauma or excessive external force applied to the area. The fracture was attributed to a combination of factors, including abutment design flaws, material fatigue, and biomechanical stress imposed on the implant during functional loading. This raises concerns about the long-term durability and reliability of titanium implants, particularly in high-stress areas such as the posterior region or weight-bearing bones. An image was made with scanning electron microscopy showing the fracture region near the prosthetic platform and highlighting the knowledge that despite their ductility, titanium implants can fracture.

Aims: This in silico study aimed to investigate the effect of implant–abutment contact surfaces on the stress generation of Morse taper implants under oblique loading. Materials and methods: Three-dimensional finite element models of Bone-Level and Tissue-Level implants were simulated with Standard and Partial contacts between the abutment and implant. The dimensional parameters followed the ISO 14801 guidelines, and an oblique load of 300 N was applied to the implants. The von Mises stress was acquired. Results: The Tissue-Level design showed a significant difference in the stress level when the connection with the implant, abutment, and screw was Partial. For the implant fixture, abutment, and screw, the Tissue-Level design showed 13% more stress in the implant, abutment, and screw when the connection was Partial. The Bone-Level design did not affect the connection and showed an overall 42% lower stress than the Tissue-Level design for the implant fixture. However, in the screw, there was a difference between the Bone-Level implants with a Standard and Partial connection. In contrast, for the Tissue-Level implant, this difference was less evident with higher stress peaks in the entire set. Conclusion: To achieve optimal outcomes, it is highly recommended to use original abutments, as they provide a more precise fit. The stress peaks were notably lower in Bone-Level implants compared to Tissue-Level implants. Furthermore, an implant–abutment connection with more contacting areas significantly reduced stress concentration, especially in Tissue-Level implant designs. By choosing well-fitting abutments, one can ensure more stable and durable implant performance with less stress.