Effects of polymerization shrinkage on the interfacial stress at resin–metal joint in denture-base: A non-linear FE stress analysis

Objectives The purpose of this study was to investigate the effects of polymerization shrinkage on stress at the interface between resin and metal in removable dentures. Methods Three-dimensional finite element models of a denture-base were studied, which consisted of acrylic occlusal rims with different heights and metal frameworks. A relaxation modulus of 1.5 GPa for the resin and a Youngʹs modulus of 220 GPa for the metal were used as the material properties. Each model was constrained at the edge of the framework on the palatal vault. Surface-to-surface contact elements were used to calculate the interfacial stress in a direction perpendicular to the bond surface under a linear shrinkage ranging from 0.41 to 0.65%. The principal stress within the resin was also calculated. Results The maximum interfacial and principal stresses within the denture-base increased with resin shrinkage. Under the lowest linear shrinkage, the mean area percentages in the resin–metal joint that showed interfacial tensile stresses over 10 and 20 MPa were 63.4 and 0%, respectively. While under the highest linear shrinkage, these mean area percentages were 98.8 and 38.1%, respectively. Negligible differences in the stresses were shown by occlusal heights. Significance The polymerization shrinkage level has a significant influence on the residual stress at the resin–metal interface. Enhancement of the bond strength on the interface can reduce the failure probability at a resin–metal joint.