Aims: To establish the minimum dimensions for a non-precious cast metal occlusal rest by using mathematical analysis. An occlusal rest in a removable partial denture (RPD) provides vertical support and allows occlusal forces to be transmitted through the long axis of the abutment tooth.
Methods: The stress status of an occlusal rest in a posterior tooth-bounded RPD resembles that of a cantilever beam under a uniformly distributed load. A mathematical model based on a short rectangular cantilever beam was derived by using the yield strengths of a cast cobalt-chromium alloy and a cast titanium alloy (Ti-6Al-4V), with an applied static occlusal force of 400 N.
Results: For the cobalt-chromium alloy, the minimum rectangular dimensions for a 2.0 mm long occlusal rest are; when the width is 2.0 mm, the depth or thickness should be at least 1.03 mm. For the titanium alloy, the minimum dimensions are; when the width is 2.0 mm, the depth or thickness should be at least 0.85 mm. A decrease in the occlusal width will increase the bending stress, requiring a thicker rest for compensation, which may lead to dentin exposure during the rest seat preparation.
Conclusion: The mathematical analysis found that the traditional spoon-shaped occlusal rest seat dimensions comply with the mechanical requirements for non-precious cast metal occlusal rests in RPDs.