Fracture Load of Polyaryletherketone for 4-Unit Posterior Fixed Dental Prostheses: An In Vitro Study

Background/Objectives: This study aimed to evaluate the mechanical properties, particularly the fracture load, modulus of elasticity, and fracture patterns, of four-unit posterior tooth-supported fixed dental prostheses (FDPs) fabricated from various computer-aided design/computer-aided manufacturing (CAD-CAM) materials. Understanding the mechanical behavior of these materials is crucial for optimizing prosthesis performance in high-load-bearing posterior regions. Methods: A total of 68 standardized FDP frameworks were fabricated, each consisting of two abutments (first premolar and second molar) and two pontics (second premolar and first molar). The specimens were divided into four groups (n = 17): polyetheretherketone (PEEK), polyetherketoneketone (PEKK), 3Y zirconia (control 1), and 4Y zirconia (control 2). All samples underwent three-point bending tests using a universal testing machine with a crosshead speed of 0.5 mm/min. Fracture patterns were assessed visually and documented. Fractured specimens were examined using scanning electron microscopy (SEM). Data were analyzed using the SPSS v20. Normality was assessed with the Shapiro-Wilk test. The fracture loads were compared using the Kruskal-Wallis test with Bonferroni correction, and the modulus of elasticity was analyzed via a one-way ANOVA with Dunnett's T3 post hoc test. A significance level of α = 0.05 was applied. Results: Significant differences were observed among the groups. The 3Y zirconia demonstrated the highest fracture load (2275 ± 511.03 N), followed by the 4Y zirconia (1034.28 ± 221.55 N), PEEK (883.21 ± 172.24 N), and PEKK (402.01 ± 127.98 N). PEEK showed ductile fracture behavior, while PEKK exhibited brittle failure. Both zirconia groups demonstrated brittle fracture patterns. Conclusions: PEEK and 4Y zirconia presented comparable fracture loads, but with differing fracture behaviors-ductile in PEEK and brittle in 4Y zirconia. The 3Y zirconia offered the highest fracture load, but with limited flexibility. PEKK showed the lowest mechanical performance. These findings highlight the importance of material selection for FDPs in posterior load-bearing areas, considering both fracture load and failure mode.