In Vitro Assessment of a New Block Design for Implant Crowns with Functional Gradient Fabricated with Resin Composite and Zirconia Insert

Abstract

This study aims to evaluate and compare the mechanical resistance, fatigue behavior and fracture behavior of different CAD/CAM materials for implant crowns. Eighty-eight implant crowns cemented-screwed with four sample groups: two monolithic G1 Zirconia (control) and G3 composite and two bi-layered G2 customized zirconia/composite and G4 prefabricated zirconia/composite. All static and dynamic mechanical tests were conducted at 37 °C under wet conditions. The fractographic evaluation of deformed and/or fractured samples was evaluated via electron microscopy. Statistical analysis was conducted using Wallis tests, which were performed depending on the variables, with a confidence interval of 95%, (p < 0.05). The Maximum Fracture Strength values displayed by the four groups of samples showed no statistically significant differences. The crown–abutment material combination influenced the failure mode of the restoration, transitioning from a fatigue fracture type located at the abutment–analog connection for monolithic materials (G1 and G3) to a brittle fracture located in the crown for bi-layered materials (G2 and G4). The use of layered crown materials with functional gradients appears to protect the crown/abutment connection area by partially absorbing the applied mechanical loads. This prevents catastrophic mechanical failures, avoiding long chairside time to solve these kinds of complications.