To compare maximum torque produced by different muscular groups and its influence on mini-implant insertion torque and fracture prevention. A prospective study involving in vivo and in vitro laboratory experiments. Eighty-seven professionals were evaluated for maximum torque produced using a screwdriver with combined action between thumb and index fingers [maximum digital torque (MDT)] and by forearm supination movement [maximum brachial torque (MBT)]. Ninety mini-implants distributed over nine different diameters and twenty commercially available mini-implants of two different diameters and trademarks were fractured to determine the fracture torque (FT). The fracture resistance index (FRI) was obtained from: FRI_MDT = FT/MDT and FRI_MBT = FT/MBT. The analysis of variance (ANOVA) and t tests were used to compare the groups. MDT was smaller than MBT and both were smaller in females. FT increased for each 0·1 mm of diameter increment. FRI_MDT was greater than FRI_MBT for all diameters. FRI_MDT>1 was found when the diameter was greater than or equal to 1·5 mm. FRI_MBT>1 occurred with diameters equal or greater than 1·7 mm for females and 1·8 mm for males. The 1.5 mm and 1.6 mm diameter of commercially available and mini-implants presented FRI_MBT<1 and FRI_MDT>1. Digital torque was 42% smaller than brachial torque, and it was mechanically safer and biologically more compatible, allowing fracture prevention of 1·5 mm or thicker mini-implant diameter due to insertion torque limitation at 15 N/cm.
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