In Vitro Assessment of Retention and Fit Precision in Cast, 3D-Printed Cobalt-Chromium and Polyether Ether Ketone Clasps Subjected to Fatigue Cycling

Objectives: This study aimed to compare the retention and fit precision of removable partial denture circumferential clasps fabricated from cast cobalt–chromium, 3D-printed cobalt–chromium, and polyether ether ketone. Methods: A maxillary right first premolar abutment was prepared. Eighty circumferential clasps were allocated into three material groups: cast Co–Cr (n = 20), 3D-printed Co–Cr (n = 20), and PEEK (n = 40). The terminal third of metal retentive clasps was designed to engage 0.25 mm and 0.50 mm undercuts. PEEK clasps were fabricated with two designs: partial (two-thirds) and full-arm undercut engagement. Each group was examined for retentive forces after 1440 cycles (simulating 1 year). Initial and final retentive forces were recorded. Clasp deformation was assessed by measuring inter-arm distance before and after cycling using digital photography and ImageJ software. Results: All clasp groups demonstrated a statistically significant reduction in retention after 1440 cycles (p < 0.05). At both undercut depths, cast and 3D-printed Co–Cr clasps exhibited significantly higher retentive forces than PEEK (p < 0.001). Within the PEEK group, full-arm engagement showed significantly higher retention than partial engagement at the 0.25 mm undercut (p < 0.001), whereas no significant difference was observed between designs at the 0.50 mm undercut (p = 0.406). Fit precision revealed a significant increase in inter-arm distance after cycling (p < 0.05). PEEK clasps exhibited significantly smaller dimensional changes than Co–Cr clasps (p < 0.02). Conclusions: Clasp material, undercut depth, and design significantly influenced retention and fit precision. Co–Cr clasps maintained higher retentive forces, whereas PEEK clasps demonstrated reduced deformation after cycling.