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Healing large bone defects, especially in weight-bearing locations, remains a challenge using available synthetic ceramic scaffolds. Manufactured as a scaffold using 3D printing technology, Sr-HT-Gahnite at high porosity (66%) had demonstrated significantly improved compressive strength (53 ± 9 MPa) and toughness. Nevertheless, the main concern of ceramic scaffolds in general remains to be their inherent brittleness and low fracture strength in load bearing applications. Therefore, it is crucial to establish a robust numerical framework for predicting fracture strengths of such scaffolds. Since crack initiation and propagation plays a critical role on the fracture strength of ceramic structures, we employed extended finite element method (XFEM) to predict fracture behaviors of Sr-HT-Gahnite scaffolds. The correlation between experimental and numerical results proved the superiority of XFEM for quantifying fracture strength of scaffolds over conventional FEM. In addition to computer aided design (CAD) based modeling analyses, XFEM was conducted on micro-computed tomography (μCT) based models for fabricated scaffolds, which took into account the geometric variations induced by the fabrication process. Fracture strengths and crack paths predicted by the μCT-based XFEM analyses correlated well with relevant experimental results. The study provided an effective means for the prediction of fracture strength of porous ceramic structures, thereby facilitating design optimization of scaffolds.

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Summary Fracture is one of the most common failure modes in brittle materials. It can drastically decrease material integrity and structural strength. To address this issue, we propose a level‐set (LS) based topology optimization procedure to optimize the distribution of reinforced inclusions within matrix materials subject to the volume constraint for maximizing structural resistance to fracture. A phase‐field fracture model is formulated herein to simulate crack initiation and propagation, in which a staggered algorithm is developed to solve such time‐dependent crack propagation problems. In line with diffusive damage of the phase‐field approach for fracture; topological derivatives, which provide gradient information for the topology optimization in a LS framework, are derived for fracture mechanics problems. A reaction‐diffusion equation is adopted to update the LS function within a finite element framework. This avoids the reinitialization by overcoming the limitation to time step with the Courant‐Friedrichs‐Lewy condition. In this article, three numerical examples, namely, a L‐shaped section, a rectangular slab with predefined cracks, and an all‐ceramic onlay dental bridge (namely, fixed partial denture), are presented to demonstrate the effectiveness of the proposed LS based topology optimization for enhancing fracture resistance of multimaterial composite structures in a phase‐field fracture context.

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Fabrication of multilayered ceramics signifies an important topic in many advanced applications aerospace and prosthetic dentistry. This paper presents a numerical approach to characterising the transient thermal responses and corresponding thermal residual stresses that are developed in the bi-layered dental ceramic crowns model under a controlled cooling rate from a temperature around its glass transition temperature (typically 550°C) to room temperature (25°C). Finite element method (FEM) is adopted to model the residual stresses in normal or rapid cooling fabrication process. The demonstrative examples take into account the effect of thickness in core veneered all-ceramic restorative prosthesis (specific porcelain bonded to an alumina or zirconia core layer), cooling rates and mismatches in temperature-dependent material properties such as thermal expansion coefficients, specific heat and Young’s modulus. The model of transient ceramic fabrication processing showed significant potential to development of optimal prosthetic devices.

Layered all-ceramic systems have been increasingly adopted in major dental prostheses. However, ceramics are inherently brittle, and they often subject to premature failure under high occlusion forces especially in the posterior region. This study aimed to develop mechanically sound novel topological designs for all-ceramic dental bridges by minimizing the fracture incidence under given loading conditions. A bi-directional evolutionary structural optimization (BESO) technique is implemented within the extended finite element method (XFEM) framework. Extended finite element method allows modeling crack initiation and propagation inside all-ceramic restoration systems. Following this, BESO searches the optimum distribution of two different ceramic materials, namely porcelain and zirconia, for minimizing fracture incidence. A performance index, as per a ratio of peak tensile stress to material strength, is used as a design objective. In this study, the novel XFEM based BESO topology optimization significantly improved structural strength by minimizing performance index for suppressing fracture incidence in the structures. As expected, the fracture resistance and factor of safety of fixed partial dentures structure increased upon redistributing zirconia and porcelain in the optimal topological configuration. Dental CAD/CAM systems and the emerging 3D printing technology were commercially available to facilitate implementation of such a computational design, exhibiting considerable potential for clinical application in the future. Copyright © 2015 John Wiley & Sons, Ltd.