Application of Carbon Fiber and Advanced Composites in Restorative Dentistry: A Study in Material Efficiency, Manufacturing viability, Market Potential and Innovation.

Abstract

This work presents a multidisciplinary evaluation of Carbon Fibre Reinforced Polyether Ether Ketone (CF-PEEK) as a core material for hybrid dental crowns, combined with lithium disilicate (E-max) veneers. The objective was to assess the mechanical, manufacturing, and economic feasibility of introducing CF-PEEK into restorative dentistry through an engineering-driven approach. A systematic literature review compared the elastic modulus, flexural strength, and density of CF-PEEK with conventional materials such as zirconia and porcelain-fused-to-metal. Results show that CF-PEEK exhibits a modulus close to natural dentin and lower density, offering improved biomechanical compatibility and reduced stress transmission. Additive manufacturing (3D printing) was identified as the most flexible and sustainable production method, minimising material waste and enabling customised crown fabrication. The study concludes that the CF-PEEK + E-max hybrid crown is mechanically viable and aligns with sustainability goals, though improvements in bonding, colour masking, and clinical validation remain necessary. This approach demonstrates how industrial engineering tools including TRIZ, QFD, and KANO can effectively guide innovation in dental materials and workflows