The Use of the FEM to Identify the Optimal Groove Dimensions Ensuring the Least Stressed Connection between a Zirconia Coping and Veneering Ceramic

Background: To examine the influence of coping notches with varying groove widths and depths on the quality of the connection with ceramic. Methods: Ten rectangular sintered zirconia (3Y-TZP) samples were etched with a neodymium-yag laser Nd:YAG. Then, a profilometer was used to test the depths and spacing of the grooves. A notch profile was used to design the shapes and spacing of the grooves based on a finite element method (FEM) simulating zirconia. The following situations were simulated: an increase in groove width from 100% to 180% and depth from 40% and 80%; and a 40% depth and width. Results: An increase of 10% in the baseline width caused an insignificant reduction of the strain in the connection. A further increase in this dimension led to a 50% increase in strain with a 40% increase in width. An increase in the groove depth by 40% reduced the strain level by 13%, while an increase in the groove depth by 80% reduced the strain level by 22%. Simultaneous deepening and widening of the groove by 40% had no significant impact on the strain level. Conclusion: Maintaining the width of the groove bottom while increasing the depth offers fewer advantages than deepening and narrowing the groove bottom.