Fatigue analysis plays a vital role in determining the structural integrity and life of a dental implant. With the use of such implants on the rise, there is a corresponding increase in the number of implant failures. As such, the aim of this research paper is to investigate the life of 3D-printed dental implants. The dental implants considered in this study were 3D printed according to the direct metal laser sintering (DMLS) method. Additionally, a finite element model was developed to study their performance, while fatigue life was predicted using Fe-Safe software®. The model was validated experimentally by performing fatigue tests. The life of the dental implants was analysed based on Normal strain and the Brown-Miller with Morrow mean correction factor algorithm. The model revealed that there was a strong correlation between the FEA and the experimental results. The clinical success of 3D-printed dental implant experimentally is 20.51 years and computationally under Normal strain is 19.89 years and Brown-Miller with Morrow mean correction factor is 26.82 years.

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The initial stability after implantology is paramount to the survival of the dental implant and the surface roughness of the implant plays a vital role in this regard. The characterisation of surface topography is a complicated branch of metrology, with a huge range of parameters available. Each parameter contributes significantly towards the survival and mechanical properties of 3D-printed specimens. The purpose of this paper is to experimentally investigate the effect of surface roughness of 3D-printed dental implants and 3D-printed dogbone tensile samples under areal height (Ra) parameters, amplitude parameters (average of ordinates), skewness (Rsk) parameters and mechanical properties. During the experiment, roughness values were analysed and the results showed that the skewness parameter demonstrated a minimum value of 0.596%. The 3D-printed dental implant recorded Ra with a 3.4 mm diameter at 43.23% and the 3D-printed dental implant with a 4.3 mm diameter at 26.18%. Samples with a complex geometry exhibited a higher roughness surface, which was the greatest difficulty of additive manufacturing when evaluating surface finish. The results show that when the ultimate tensile stress (UTS) decreases from 968.35 MPa to 955.25 MPa, Ra increases by 1.4% and when UTS increases to 961.18 MPa, Ra increases by 0.6%. When the cycle decreases from 262142 to 137433, Ra shows that less than a 90.74% increase in cycle is obtained. For 3D-printed dental implants, the higher the surface roughness, the lower the mechanical properties, ultimately leading to decreased implant life and poor performance.