A 3D printed ultra-short dental implant based on lattice structures and Zirconia/Ca₂SiO₄ combination

Additive Manufacturing (AM) enables the generation of complex geometries and controlled internal cavities that are so interesting for the biomedical industry due to the benefits they provide in terms of osseointegration and bone growth. These technologies enable the manufacturing of the so-called lattice structures that are cells with different geometries and internal pores joint together for the formation of scaffold-type structures. In this context, the present paper analyses the feasibility of using diamond-type lattice structures and topology optimisation for the re-design of a dental implant. Concretely, a new ultra-short implant design is proposed in this work. For the manufacturing of the implant, digital light processing additive manufacturing technique technology is considered. The implant was made out of Nano-zirconia and Nano-Calcium Silicate as an alternative material to the more common Ti6Al4V. This material combination was selected due to the properties of the calcium-silicate that enhance bone ingrowth. The influence of different material combination ratios and lattice pore sizes were analysed by means of FEM simulation. For those simulations, a bio-material bone-nanozirconia model was considered that represents the final status after the bone is integrated in the implant. Results shows that the mechanical properties of the biocompatible composite employed were suitable for dental implant applications in dentistry. Based on the obtained results it was seen that those designs with 400 μm and 500 μm pore sizes showed best performance and led to the required factor of safety.