Three-Dimensional Finite Element Analysis (FEM) of Tooth Stress: The Impact of Cavity Design and Restorative Materials

Finite element analysis has been widely applied in restorative dentistry, but there is limited evidence directly comparing the biomechanical behavior of amalgam and bulk-fill composite resins in standardized cavity designs. This study aimed to evaluate the stress distribution in enamel, dentin, and restorative materials under different cavity configurations and filling materials. A 3D model of a maxillary molar was reconstructed from dental tomography using Geomagic Design X 2020. Four cavity models were created with Solidworks 2013: Class I (occlusal, Group A), Class II disto-occlusal (Group B), Class II mesio-occlusal (Group C), and Class II mesio-occluso-distal (Group D) cavities. Each model was restored with either amalgam or bulk-fill composite and a 600 N occlusal force was applied. Maximum principal stresses were analyzed with ABAQUS software. The highest stress was observed in the bulk-fill composite restoration of the Class II MO cavity (231 Mpa), whereas the lowest stress occurred in amalgam restoration of Class I cavity. Overall, amalgam restorations showed lower stress concentrations than bulk-fill composites, especially in complex cavity designs. These results suggest that cavity configuration and restorative material selection influence stress distribution and may impact the long-term biomechanical stability of restored teeth.