Optimizing the design of bio-inspired functionally graded material (FGM) layer in all-ceramic dental restorations

Due to elastic modulus mismatch between the different layers in all-ceramic dental restorations, high tensile stress concentrates at the interface between the ceramic core and cement. In natural tooth structure, stress concentration is reduced by the functionally graded structure of dentin-enamel junction (DEJ) which interconnects enamel and dentin. Inspired by DEJ, the aim of this study was to explore the optimum design of a bio-inspired functionally graded material (FGM) layer in all-ceramic dental restorations to achieve excellent stress reduction and distribution. Three-dimensional finite element model of a multi-layer structure was developed, which comprised bilayered ceramic, bio-inspired FGM layer, cement, and dentin. Finite element method and first-order optimization technique were used to realize the optimal bio-inspired FGM layer design. The bio-inspired FGM layer significantly reduced stress concentration at the interface between the crown and cement, and stresses were evenly distributed in FGM layer. With the optimal design, an elastic modulus distribution similar to that in DEJ occurred in the FGM layer.