Experimental and 2-Step Finite Element Analysis of Cyclic Fatigue Resistance of Conventional and Heat-Treated Rotary Endodontic Nickel-Titanium Instruments

Background: To evaluate the cyclic fatigue resistance of rotary endodontic nickel-titanium instruments using both experimental and finite element methods. Methodology: Four different proprietary rotary endodontic instruments (PTG, PTU, VB, and TRN) were subjected to cyclic fatigue tests through a custom-built fixture (n = 30 for each group) and tested until failure according to the manufacturer’s recommended settings, and the number of cycles to failure (NCF) was measured. Separated fragments were measured to determine the location of the fracture event. Finite element modeling replicated this experiment in silico via a two-step method, modeling the dynamic motion via an initial insertion step, then followed by rotation. Results: TRN showed the highest NCF (2027.94 ± 452.50) with the lowest values for strain (4.49% ± 0.23%) and fragment lengths (3.26 mm ± 0.47 mm), whereas PTU showed the lowest NCF (600.90 ± 80.86) and highest values for strain (6.29% ± 0.47%) and fragment lengths (5.36 mm ± 0.79 mm). All instruments showed an increase in von Mises and maximum principal stress during the insertion step but showed no changes to the maximum stress values during the rotational step. Conclusions: The finite element analysis approach used provided useful insights into the stress evolution and stress distribution of instruments during cyclic fatigue but lacked the ability with existing inputs to predict failure from cyclic fatigue.