14:I[94367,["/_next/static/immutable/chunks/4370mg0uq-myq.js","/_next/static/immutable/chunks/0q7ni_ir0mogv.js","/_next/static/immutable/chunks/0q9_4lzwjwc3f.js","/_next/static/immutable/chunks/1p8rnjckwz-06.js","/_next/static/immutable/chunks/3zikwth1q5z_-.js","/_next/static/immutable/chunks/0eigul57_x91p.js","/_next/static/immutable/chunks/3r0kxtkfnobr8.js","/_next/static/immutable/chunks/260mvqou7a4l3.js","/_next/static/immutable/chunks/14bkwvgoktej3.js"],"NewsDetailPage"] 15:T1656,

Scientists at the International Advanced Research Centre for Powder Metallurgy and New Materials (ARCI), an autonomous institute under the Department of Science and Technology (DST), have developed a bi-layered dental implant combining titanium alloy and zirconia into a single structure. The design aims to reduce the number of surgical procedures typically required for dental implants while improving durability and biocompatibility. The research was originally published in the journal Materials Letters and was recently highlighted by the DST as an example of indigenous biomedical device development.

Traditional dental implants consist of three separate components: a fixture embedded in the jawbone, an abutment connecting the fixture to the crown, and the crown itself. These multi-part assemblies are prone to micromovements at the abutment interface, which can compromise osseointegration — the process by which the implant fuses with the jawbone — and lead to implant loosening over time. Such systems also typically require two to three separate surgical procedures, adding to patient discomfort and clinical complexity.

While titanium alloys and zirconia are both widely used in dental implants for their biocompatibility and mechanical strength, each has drawbacks. Titanium alloy (Ti6Al4V) can be susceptible to corrosion and gum recession in the mouth's moist environment, while zirconia — though aesthetically favourable and corrosion-resistant — can degrade over time due to hydrolysis, affecting its long-term stability.

To address these limitations, the ARCI team engineered a single-piece structure in which titanium alloy forms the load-bearing fixture for jawbone integration, while zirconia forms the crown region, providing wear resistance and aesthetic appeal.

The implant was fabricated using Spark Plasma Sintering (SPS), an advanced powder metallurgy technique. A custom-designed tapered graphite die enabled precise temperature control during the sintering process, allowing the two materials — despite having widely different sintering temperatures — to be densified simultaneously. This approach achieved a density of 99.5%, producing a strong, defect-free bi-layered structure in a single processing step.

Following sintering, researchers conducted machining trials using a 5-axis CNC machine to shape the threaded implant. Some challenges related to tool movement along curved surfaces were noted, and the team said process optimisation is currently ongoing.

Structural analysis confirmed a well-bonded interface between the two materials, with no cracks, delamination, pores, or secondary phases detected. The zirconia layer showed fine grains of approximately 0.3 micrometres, while titanium alloy grains near the interface were refined to 0.3–1 micrometres compared to the bulk material. No significant elemental diffusion was observed across the interface, indicating a stable transition zone between the ceramic and metal layers.

Mechanical testing showed the bi-layered structure achieved a hardness of up to 1350 HV, compressive strength of approximately 1550 MPa, and flexural strength of approximately 310 MPa — figures the researchers say are comparable to or exceed those of commercial implant materials.

Biological safety testing included MTT assays (a colorimetric test measuring cellular metabolic activity) using mouse fibroblast cells, which showed metabolic activity exceeding 90% across all tested concentrations — above the minimum threshold considered safe for biomaterials. Hemolysis testing showed negligible red blood cell damage, supporting the material's suitability for dental use.

According to the researchers, integrating mechanical strength, corrosion resistance, aesthetic performance, and biological safety into a single-piece structure could reduce the number of surgical interventions required for implant placement while improving long-term stability. The institute said the fabrication process is highly reproducible and suitable for scaling to industrial production, positioning the innovation as a contribution to India's push for affordable, indigenously developed dental implants.

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