Influence of CAD/CAM Fabrication and Sintering Procedures on the Fracture Load of Full-Contour Monolithic Zirconia Crowns as a Function of Material Thickness

Abstract

Summary Objective: The purpose of this in vitro study was to analyze the effect of computer-aided design/computer-aided manufacturing (CAD/CAM) fabrication and sintering procedures on the fracture load of monolithic zirconia crowns with different material thicknesses adhesively seated to methacrylate dies fabricated with stereolithography technology. Method: Monolithic zirconia crowns were fabricated from inCoris TZI C material with a chairside CAD/CAM system (CEREC MCXL) comprising three material thicknesses (0.5/1.0/1.5 mm, n=8 each). Two CAD/CAM fabrication procedures (milling, MI; grinding, GR), two chairside sintering procedures (superspeed, SS; speedfire sintering, SF), and one labside sintering procedure (classic, CL) were evaluated. In total, 144 crowns were fabricated. Restorations were adhesively seated to methacrylate dies fabricated with SLA technology. Thermomechanical cycling (TCML) was performed before fracture testing. Loading forces until fracture were registered and statistically analyzed with one-way analysis of variance (ANOVA), post hoc Scheffé test, and three-way ANOVA (α=0.05). Results: Test groups showed statistically significant differences (p<0.05). The highest mean value was found for 1.5-mm crowns of group GR_SF with 3678.6 ± 363.9 N. The lowest mean value was found for group 0.5-mm crowns of group MI_SF with 382.4 ± 30.7 N. There was a significant three-way interaction effect between thickness, sintering, and processing [F(4,126)=9.542; p<0.001; three-way ANOVA, significance level α=0.05]. Conclusions: CAD/CAM fabrication and sintering procedures influence the maximum loading force of monolithic zirconia crowns with different material thicknesses. A material thickness of 0.5 mm should be considered as a critical thickness for monolithic zirconia crown restorations.