Prediction of permanent deformation in cast clasps for denture prostheses using a validated nonlinear finite element model

Objectives Permanent deformation is one of the most common mechanical complications that affect denture clasps. This can lead to loss of retention and stability of the prosthesis. The purpose of this study was to apply and validate a nonlinear finite element model for permanent deformation prediction in cast denture clasps. Such a model can enhance the process of design optimization and contribute to minimizing the possibility of this problem. Methods Cast clasps made from Ti–6Al–7Nb, Co–Cr and Type IV gold alloys were loaded in three different directions (outside, inside and outside inclined 30°), and the resulting permanent deformation values were recorded. Nonlinear finite element analysis simulations based on the maximum distortion energy criterion for yielding, were conducted for clasp models that were reproduced according to the dimensions of each experimental specimen. Linear regression analysis for the results of the experiment and simulation was performed to verify the validity of the mathematical models. Results Deflections required to produce specific amounts of permanent deformation were in close agreement with those recorded experimentally. The R2 value for all bending tests was 0.985 and the linear regression equation expressed in micrometers was [DeflectionFEA = 0.976 (DeflectionReal) + 34]. Significance Permanent deformation behavior in the cast clasps with a relatively wide range of deflections (0–2 mm) can be predicted using the proposed model, which shall enhance the design optimization process of cast clasps for denture prostheses.