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The effect of a restored machined hybrid dental ceramic crown–tooth complex is not well understood. This study was conducted to determine the effect of the stress state of the machined hybrid dental ceramic crown using three-dimensional finite element analysis. Human premolars were prepared to receive full coverage crowns and restored with machined hybrid dental ceramic crowns using the resin cement. Then, the teeth were digitized using micro-computed tomography and the teeth were scanned with an optical intraoral scanner using an intraoral scanner. Three-dimensional digital models were generated using an interactive image processing software for the restored tooth complex. The generated models were imported into a finite element analysis software with all degrees of freedom concentrated on the outer surface of the root of the crown–tooth complex. To simulate average occlusal load subjected on a premolar a total load of 300 N was applied, 150 N at a buccal incline of the palatal cusp, and palatal incline of the buccal cusp. The von Mises stresses were calculated for the crown–tooth complex under simulated load application was determined. Three-dimensional finite element analysis showed that the stress distribution was more in the dentine and least in the cement. For the cement layer, the stresses were more concentrated on the buccal cusp tip. In dentine, stress was more on the cusp tips and coronal 1/3 of the root surface. The conventional crown preparation is a suitable option for machined polymer crowns with less stress distribution within the crown–tooth complex and can be a good aesthetic replacement in the posterior region. Enamic crowns are a good viable option in the posterior region.

Three-Dimensional Finite Element Analysis of Stress Distribution in a Tooth Restored with Full Coverage Machined Polymer Crown