journal of dentistry 41 (2013) 412419

Available online at www.sciencedirect.com

journal homepage: www.intl.elsevierhealth.com/journals/jden

Three-dimensional finite element modelling of all-ceramic

restorations based on micro-CT
lvaro Della Bona a,*, Marcia Borba a, Paula Benetti a, Yuanyuan Duan b, Jason A. Griggs b
A
a
b

University of Passo Fundo, Post-graduate Program in Dentistry, Passo Fundo, RS, Brazil
Department of Biomedical Materials Science, University of Mississippi Medical Center, Jackson, MS, USA

article info

abstract

Article history:

Objectives: To describe and apply a method of modelling dental crowns and three-unit fixed

Received 20 November 2012

partial dentures (FPD) for finite element analyses (FEA) from 3D images obtained using a

Received in revised form

micro-CT scanner.

26 February 2013

Methods: A crown and a three-unit fixed partial denture (FPD) made of a ceramic framework

Accepted 27 February 2013

(Y-TZP) and veneered with porcelain (VM9) were scanned using an X-ray micro-CT scanner
with a pixel size of 6.97 mm. Slice images from both structures were generated at each
0.034 mm and processed by an interactive image control system (Mimics). Different masks

Keywords:

of abutments, framework and veneer were extracted using thresholding and region growing

Finite element analysis

tools based on X-ray image brightness and contrast. 3D objects of each model were

Zirconia

incorporated into non-manifold assembly and meshed simultaneously. Volume meshes

Non-destructive testing

were exported to the FEA software (ABAQUS), and the load-generated stress distribution was

X-ray microtomography

analyzed.
Results: FEA models showed great shape resemblance with the structures. The use of nonmanifold assembly ensured matching surfaces and coinciding nodes between different
structural parts. For the crown model, tensile stresses were concentrated in the internal
surface of the core, near to the applied load. For the FPD model, the highest tensile stresses
were located in the framework, on the cervical area of connectors and pontic.
Conclusions: Valid 3D models of dental crown and FPD can be generated by combining microCT scanning and Mimics software, emphasizing its importance as design tool in dental
research.
Clinical significance: The 3D FEA method described in this work is an important tool to predict
the stress distribution, assisting on structural design of dental restorations.
# 2013 Elsevier Ltd. Open access under the Elsevier OA license.

1.

Introduction

The clinical behaviour of restorative materials can be

estimated using in vitro and in vivo tests. Randomized clinical
trials can provide reliable information on the prognosis of

prosthetic restorations. However, time is necessary to collect

data, the cost is high and a large number of volunteers is
required to obtain adequate statistical power.1,2 Thus, laboratory simulations are important tools to obtain fast and
standardized results.2 Although simplified specimens, such
as disks and micro-bars, used in these in vitro tests are useful

* Corresponding author at: Post-graduate Program in Dentistry, Dental School, University of Passo Fundo, Campus I, BR285, km 171, Passo
Fundo, RS, Brazil. Tel.: +55 54 3316 8395.
. Della Bona).
E-mail address: dbona@upf.br (A
0300-5712 # 2013 Elsevier Ltd. Open access under the Elsevier OA license.
http://dx.doi.org/10.1016/j.jdent.2013.02.014

journal of dentistry 41 (2013) 412419

to determine materials strength and to predict local stresses

that could lead to clinical failure, they tend to underestimate
the influence of the restoration geometry in the stress
distribution.3,4
When specimens that simulate the shape of crowns and
fixed partial dentures (FPDs) are used, the mechanical
behaviour may be closer to the clinical situation, but the
evaluation of the stress distribution within complex geometries is limited.57 This situation can be overcome using finite
element analysis (FEA), which is a fast and a relatively low cost
method used to investigate stress distribution and strain
patterns of complex structures, such as dental restorations.8
FEA can be used for two different purposes: (1) to understand
the failure behaviour of complex structures, or (2) to optimize
the experiments through the mathematical simulation and
selection of the best design to perform the test.9
The basic steps involved in this method are pre-processing,
solving and post-processing.10 The pre-processing stage
consists of geometric modelling of a structure, discrimination
of a model into smaller elements connected by nodes using
the proper selection of an element type and assigning the
material properties. The final step in pre-processing is the
application of external forces, pressure, thermal changes, or
other factors; and displacement constraints at specified
nodes.11 The computer software solves a set of simultaneous
equations with thousands of variables to achieve the desired
results. The post-processing stage consists on the graphical
presentation of results, including qualitative and numerical
results.
Pre-processing is a critical step, especially when anatomical shapes and layered structures are required. This stage is
usually time-consuming and is prone to errors due to
limitations of the geometry acquisition methods (i.e. manual
tracing of tooth sections, digitization of a plaster model).12,13
To overcome limits of computational power or difficulties
associated with complex geometry many studies simplified
the calculations using 3D models with coarse meshes14;
axisymmetric geometries15,16 or 2D models,1719 which can
simulate the stress state at clinical failure. However, simplified
geometries could induce false predictions when inadvertently
applied.20,21 Thus, sophisticated techniques have been developed, in which an optimization of the model design is
performed from micro-computed tomography (micro-CT).22
Micro-CT is a non-destructive technology that allows
image acquisition with high spatial resolution.9,23 Therefore,
small objects such as teeth, dental implants, dental crowns
and FPDs could be accurately reproduced.5,12,24 The differences in the linear attenuation coefficient among the
materials that constitute the scanned structure are responsible for X-ray image contrast, which allows the identification of
the different layers.23,25 Important information on the internal
geometric properties and structural parameters of the specimen can be obtained. Thus, it is possible to generate models
with refined geometries, minimizing errors in the FEA and
reducing the risk of false predictions.9,12,22
Although previous studies reported the development of
valid and complex 3D element models using microCT,5,12,13,21,22,26 there is still a lack of information related to
the modelling process of prosthetic restorations using this
methodology. Therefore, the objective of this study was to

413

describe the sequential software processing used to obtain a

three-dimensional finite element model of all-ceramic crowns
and FPD based on images provided by micro-CT scanning,
simulating the stress distribution of the restorations under
load.

2.

Materials and methods

2.1.

Micro-CT scanning

Scanning was performed using a SkyScan 1172 micro-CT

scanner with a 10 megapixel camera (Skyscan, Aartselaar,
Belgium). To produce the single-unit model, a monolithic
porcelain crown and a framework from a left upper first molar
crown were scanned. To produce the FPD model two parts
were scanned separately: (1) a stainless steel die simulating
prepared teeth and (2) a three-unit all-ceramic FPD (9 mm2
connector cross-section). Both crown and FPD were made by
an yttria partially stabilized zirconia-based (Y-TZP) ceramic
framework (Vita In-Ceram YZ, Vita Zahnfabrik, Germany) and
a feldspathic porcelain (Vita VM9, Vita Zahnfabrik, Germany).
The scanning parameters were: accelerating voltage of
100 kV, current of 100 mA, exposure time of 2950 ms per frame,
Al + Cu filter, and rotation step at 0.48 (1808 rotation). For the
metal dies, the X-ray beam was irradiated perpendicularly to
the preparation long axis and, for the dental restorations, the
beam was parallel to their long axis. The image pixel size was
6.97 mm. The X-ray projections were reconstructed to form a
3D model, which was saved as a stack of bmp-type files using
NRecon software (Skyscan, Aartselaar, Belgium). Beam hardening correction of 80% and ring artefact correction of 7 were
used for the reconstruction.

2.2.

Mesh generation

Tomography images of the structures were generated at each

0.034 mm and processed by an interactive medical image
control system (Mimics 13.0, Materialize, Belgium). Mimics
system imports all CT data in a wide variety of formats and
displays the objects in three views. The software presents
segmentation functions based on image density thresholds.12

2.2.1.

Dental crown

Masks of the framework and the veneer were obtained using

thresholding and region growing tools based on the image
value. The 3D object representing the zirconia framework was
subtracted from the monolithic porcelain crown object to
obtain a perfectly fitted veneer part. The mask of the master
die was created using Boolean operations by adding two
different masks: the internal space of the crown (cavity fill
tool) and a cylinder drawn at the bottom surface (Fig. 1).

2.2.2.

Fixed partial denture

The micro-CT files corresponding to the metal dies and the

FPD were processed separately to reduce the amount of
manual work necessary to built three different masks with
Mimics software. A mask of the dies was obtained though
brightness and contrast adjustment, and a 3D object was
produced and converted into a STL file. For the FPD,

414

journal of dentistry 41 (2013) 412419

Fig. 1 Cross-section images of masks from different perspectives (AC). 3D objects were created to represent the framework
(D), the veneer (E) and the die (F).

segmentation based on image density thresholding of different value scale intensity levels was used to generate two
masks, corresponding to the framework and the veneering
layer. 3D objects were obtained for the framework and the
veneer. The metal dies STL file was imported to the FPD file
(Fig. 2AC), making for a three-part final file: metal dies,
framework and veneer (Fig. 2DF).
The masks of each part of the models were separately
converted into STL files (stereolithography, bilinear and
interplane interpolation algorithm), which are improper for
FEA because of the amount and shape of the triangles. Thus,
for both models (crown and FPD), the files of different parts

were incorporated into non-manifold assembly in Mimics, and

edited simultaneously. The parts were remeshed with a
maximum geometrical error of 0.05%, maintaining the original
geometry. Wrapping and smoothing operations were used to
remove undesired sharp edges. The mesh quality was defined
by controlling triangle edge length, the ratio between height
and base of the triangles and removing sharp triangles using a
triangle filter, so that the file could be imported into the FEA
software without generating errors. Subsequently, the objects
were separated according to the original parts and volumetric
meshes were generated and imported by the FEA software
(ABAQUS V6.8, Simulia, USA).

Fig. 2 Cross-section images of dies, framework and veneer masks from different perspectives (AC) and 3D objects
representing: (D) metal dies; (E) framework and (F) veneer.

journal of dentistry 41 (2013) 412419

415

2.3.
Materials properties, boundary conditions, and
analysis
2.3.1.

Dental crown

The final model was composed by tetrahedral elements

(compatible with 3D modelling) and three layers: (1) epoxy
resin die, with elastic/plastic behaviour similar to dentine; (2)
zirconia core (Y-TZP) and (3) porcelain layer (VM9).
The bottom surface nodes of abutment meshes were
constrained (no displacement) in the three spatial dimensions.
Interfaces between meshes were considered perfectly bonded
in Constraint Manager. An axial compressive load of 100 N was
uniformly applied in 10 nodes (10 N each) of a 2-mm diameter
area of the palatal cusp, simulating the opposing tooth contact
in a wear facet.

2.3.2.

3.

Results

Fixed partial denture

The final FPD model was composed of tetrahedral elements

and three layers: (1) metal dies (stainless steel); (2) ceramic
framework (Y-TZP) and (3) porcelain layer (VM9). Two
interfaces were created, between the metal dies and the
framework and between the framework and the porcelain
layer. The cement layer was neglected.
Nodes in the bottom surface of the dies were fixed in all
directions; no rotation or translation was allowed. A compressive load, perpendicular to the restoration long axis, was
applied in the centre of the occlusal surface of the pontic. A
load of 200 N was distributed uniformly over 20 nodes located
in a circular area with 3 mm diameter.
The following considerations were made to facilitate the
FEA analyses: (1) the materials were considered to be isotropic
and homogeneous and to have a linear elastic behaviour; (2)
the effects of the periodontal ligament and pulp chamber were
not considered; (3) elastic modulus (E); and Poissons ratio (v)
were maintained constant. The values of the material
properties used to perform the analysis are presented in
Table 1.16,27,28
The stress distributions from the linear finite element
analyses were evaluated according to the location and
magnitude of the maximum first principal stress.

2.3.3.

Fig. 3 Stress distribution in the core: top (A) and bottom (B)
images.

Verification of models accuracy

Pre-determined points were chosen and used as reference to

measure the dimension of the physical crown and FPD and the
dimension of the FEA models. A digital calliper was used to
measure the structures. The dimensions of the FEA models
were computed using the measuring tool of Mimics software.
The difference between the dimension of the physical
structure and the FEA model at the pre-determined points
were calculated to obtain the maximum dimensional error (%).

The 3D model showed great physical resemblance with the

structure of the crown and FPD. Comparative measurements
revealed that the dimensional error of this micro-CT based
FEA modelling did not exceed 1.64%. The use of non-manifold
assembly ensured matching surfaces and coinciding nodes
between different parts.
For the crown model, tensile stresses were concentrated
mainly at the intaglio (cementation) surface of the core, in the
area directly opposed to the load site (Fig. 3), and in the
external surface of the veneer, near to the loading area (Fig. 4).
Stress distribution in the crown can be observed in Figs. 3 and
4.
For the FPD, the highest tensile stresses were located in the
cervical area of connectors and pontic within the framework
layer. Tensile stresses of lower magnitude were also found in
the margins of the copings and in the occlusal surface of the
connectors (Fig. 5). Similar stress distribution was observed
within the porcelain layer (Fig. 6).

4.

Discussion

FEA represents a powerful tool to understand the mechanical

behaviour of all-ceramic crowns and FPDs and to optimize the
design of future tests.9 However, the analysis may be limited
by difficulties related to model generation.13 To overcome this
problem, the present study described a modelling technique,
combining micro-CT images and interactive medical image
control software, which resulted in valid 3D FEA models.

Table 1 Materials properties attributed to the models.

Material
Yttrium-partially stabilized zirconia-based
ceramic (Y-TZP)31
Feldspathic veneering ceramic (Vita VM9)31
Epoxy resin32
Stainless steel13

E (GPa)

209

0.32

67
14.9
190

0.21
0.31
0.27

Fig. 4 Stress distribution in the veneer: top (A) and bottom

(B) images.

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journal of dentistry 41 (2013) 412419

Fig. 5 Stress distribution in the FPD framework: lateral (A), cervical (B) and occlusal (C) images.

The micro-CT scanner was developed in the 1980s for

laboratory purposes on small samples and material experiments and emerged as a potential key tool in dental research.
Many advantages are related to this technology: (1) relative
ease of using equipment and software; (2) fast and nondestructive method9,26; (3) high resolution23; (4) 3D reconstruction of complex structures (i.e. bone, root canal, dental

restorations); and (5) quantitative and visual measurements

for biomaterials.11,2224 On the other hand, it is important to
emphasize that the micro-CT technique is sensitive to the
experience and knowledge of the operator. Individual parameters related to the scanning process (i.e. exposure time, filter,
rotation) and to the image reconstruction (i.e. beam hardening
and ring artefact) can influence dimensional results and

Fig. 6 Stress distribution in the FPD porcelain layer: lateral (A) and cervical (B) images.

journal of dentistry 41 (2013) 412419

produce significant errors.22,26,29 Despite the fact that some

systems are capable of reading micro-CT data and converting
them to a finite element model, many programs have limited
tools to select and edit the parts of interest. The Mimics
software was used as an interface between the micro-CT
scanning and the FEA software (ABAQUS) to fulfil the
requirements for creating accurate and highly detailed FE
models.30
It is worth mentioning that comparisons of the magnitude
of tensile stresses obtained for the crown model with the FPD
simulation were avoided because the stress state of cemented
restorations is known to be influenced by (1) restorations
design and processing; (2) ceramic thickness ratio; (3) elastic
modulus of the abutment material; and (4) cement thickness.4,3135 Different abutment materials for the crown and
FPD simulations were used for didactic purposes, simply
demonstrating the particularities on images obtainment from
scanning different materials. In addition, differences among
boundary conditions for both simulations are justified by the
fact that this research is part of a larger project that involves
mechanical testing of crowns and FPDs and the FEA design
corresponded to the physical test. However, the aim of the
present manuscript was solely to describe the technique used
to produce the FEA models.
The clinical failure of ceramic crowns was reported to
initiate from flaws and cracks existent at the cementation
(intaglio) surface directly opposed to the wear facets.4,32,3638
Therefore, this area of the crown was expected to present
concentration of tensile stresses, which were observed in the
FEA results. Both clinical observations and FEA results suggest
that the stress state of the crown is determined by the
compressive loads applied to the occlusal surface, which
cause bending of the crown, producing tensile stresses at its
interface with the abutment. Thus, damage to the cementation surface, such as the damage produced by burs or
sandblasting, should be avoid. Tensile stresses were also
observed at the near-loading area in the veneer surface of the
crown, which is in agreement with data previous reported in
literature.8,39 However, clinical observations provided strong
evidence that catastrophic failures are unlikely to initiate from
the occlusal surface, thus tensile stress in this area does not
seem to be as critical for fracture development as the stresses
at the intaglio surface.4,32,3638
Recent clinical investigations on all-ceramic restorations
reported higher number of bulk fractures (core and porcelain)
for alumina-based frameworks than for zirconia, which
presented a significant amount of veneer fractures (cracking,
chipping and delaminations) during a three-year follow-up
time.40,41 Several reasons have been reported in relation to the
origin of ceramic veneer fractures, which include restoration
design,42,43 ceramicceramic bonding conditions,44 loading
components,43 materials mechanical and thermal behaviour,
specifically residual stresses originated from the mismatch on
materials properties during the restoration processing.45
For FPDs, clinical investigations19,46 and FEA suggested that
the highest tensile stresses were located in the connectors
cervical area.15,17,19,47 These results are in agreement with the
stress distribution observed in the present study for the FPD
model. Kelly et al.19 performed a fractographic analysis of allceramic FPDs that failed in vivo and in vitro and observed that

417

in 7078% the fracture initiated at the frameworkveneer

interface, in the connector cervical area. Another study
investigated the fracture behaviour of all-ceramic zirconiabased FPDs that failed clinically46; and the authors also
reported, for most cases, that the flaw origin was located on
the cervical area of the connectors, and, for one case, the flaw
origin was located at the margin of the crown. This finding is
also in agreement with the present FEA investigation, in which
tensile stresses were also observed at the crown margin.
It is important to notice that, in the present study, high
tensile stress concentration was not only located on the FPDs
connectors but also in the cervical area of the pontic. These
results are related to the boundary conditions, not to the FE
model. The FPD geometry and the fact that the load was
applied in the centre of the pontic induced a stress distribution
similar to a three-point bending bar, in which a non-uniform
stress distribution is created. Thus, the maximum tensile
stress was located on the lower surface directly below the
applied load.19 A similar behaviour was observed in the
present study. The fact that the abutments were rigid in the
simulation also influenced the stress distribution. If rotation
and translation of the abutments were allowed, maximum
tensile stresses would, probably, be within the connector, in
the interface between porcelain and framework.19
Fischer et al.15 used FEA to evaluate the stress distribution of
all-ceramic FPDs produced with different framework materials
and connector cross-section dimensions. The authors observed
similar stress distribution among the framework materials.
Rotation of the model in the y-axis was allowed to simulate the
fisiologic movement of the teeth. Thus, the maximum principal
stress was located at the cervical area of the connectors and it
was possible to observe an increase of the tensile stress
concentration with the decrease of the connector size. As high
tensile stress concentration is located at the FPDs connectors,
the restoration should be design with an appropriate connector
size and shape.48
To extrapolate the results observed with FEA to the clinical
situation it is important to consider the degree of reality in the
model and its validity, which refers to the accuracy of the
model to represent adequately the stress patterns within the
structures.5 Considering the degree of reality of the simulation, it is important to emphasize that the FEA models
presented a few simplifications when compared with the
clinical situation: (1) materials were considered homogeneous,
isotropic and with a linear elastic behaviour; (2) the influence
of the cement layer was neglected; (3) the effect of periodontal
ligament was not considered; and (4) residual stresses induced
by the materials thermal mismatch were not considered.
Besides these factors, the flaws that were present in the
materials and the interface were not considered in the
simulation.
On the other hand, as the stress distribution observed for
the crown and the FPD was consistent with the results
reported in clinical studies, which demonstrated failure
originating from the cementation surface for the crowns
and from the connectors and pontic area for the FPD, the two
models produced in this study should be considered valid. It is
also true that there are no simple analytical solutions for
analyzing the stress distributions in specimens with complex
geometries.

418

5.

journal of dentistry 41 (2013) 412419

Conclusion

Anatomically accurate three-dimensional finite element

models of a dental crown and 3-unit FPD can be generated
by combining micro-CT scanning and Mimics software
interactive tools.
Tensile stresses were observed in the crown at the nearload area of the veneer and at the internal surface of the core.
In addition, for the applied load, the highest tensile stress
concentration in the FPD was located in the framework
material, on the cervical area of the connectors and pontic.

Conflict of interest
The authors declared that there is no conflict of interest.

Acknowledgements
The authors acknowledge theBrazilian Agencies FAPESP (2008/
58775-0), CAPES and CNPq (302364/2009-9) for the financial
support of the present research.
This investigation was also supported in part by research
grants DE013358 and DE017991 from the NIH-NIDCR.

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