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International Arab Journal of Dentistry

Abstract

Introduction: Polyetheretherketone (PEEK) implant scanbodies (ISBs) offer favorable optical properties for digital impressions but may be susceptible to wear and dimensional changes with repeated clinical use and sterilization. While previous studies have examined these variables separately, no investigation has simultaneously evaluated their combined effects on abutment-level PEEK ISBs in complete-arch implant situations.

Aim: To evaluate the effect of multiple uses and autoclave sterilization of abutment-level PEEK implants can bodies on the trueness of complete-arch intraoral digital scans in an in vitro setting.

Methods: A maxillary edentulous reference cast with four implants in an All-on-4 configuration was fabricated and digitized to generate a reference dataset. Four abutment-level PEEK ISBs were subjected to 30 cycles of intraoral scanning, disinfection, and autoclave sterilization (134°C for 3 min). For each cycle, 3D deviation of flat surfaces, whole body deviation, angular deviation, and linear inter-implant deviation were computed by superimposing experimental scans onto the reference dataset. ISBs were examined under optical microscopy at cycles 0, 10, 20, and 30 to assess surface wear. Statistical analyses included linear regression, categorical cycle comparisons, and nonparametric tests for microscopy scoring (α = .05).

Results: Across the 30 cycles, trueness of both flat surfaces (mean RMS 0.050 mm) and whole scan bodies (mean RMS 0.065 mm) remained stable and within clinically acceptable limits (< 0.1 mm). Linear deviations between scan bodies showed no progressive drift and remained ≤ 0.15 mm. Angular deviation demonstrated localized sensitivity: site 22 showed a significant increase over cycles (+0.015°/cycle; P < .001), while site 25 exhibited a slight reduction (P = .03). Microscopic evaluation revealed progressive surface wear across all ISBs (Friedman test p = 0.017), with one scanbody exhibiting severe structural deformation (Score 4) at the intaglio-abutment interface by 30 cycles.

Conclusions: Repeated autoclave sterilization and reuse of abutment-level PEEK implants can bodies up to 30 cycles did not negatively affect trueness or linear accuracy of complete-arch digital impressions for the majority of cases. Small site-specific changes in angular deviation were observed. Despite progressive surface wear, functional geometry was largely maintained, though structural deformation occurred in one instance.

Clinical implications: Abutment-level PEEK implant scanbodies can be reused for multiple cycles after autoclave sterilization without clinically relevant degradation in digital impression accuracy for most cases, potentially reducing material waste and costs. However, clinicians should remain cautious in anterior regions where angular precision is critical and be vigilant for signs of severe wear.

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