Evaluation of the Milling Accuracy of Zirconia-Reinforced Lithium Silicate Crowns Fabricated Using the Dental Medical Device System: A Three-Dimensional Analysis

3D-printed zirconia orthodontic brackets: Effect of printing method on dimensional accuracy

OBJECTIVES

This study investigated the effect of additive manufacturing (AM) methods on the slot height dimensions and accuracy of 3D-printed orthodontic brackets.

METHODS

A 3D model of a standard Mclaughlin Bennett Trevisi bracket was used as a reference to print the ceramic bracket in a 90° orientation using two representative AM methods: digital light processing (DLP) and material jetting (MJ). The dimensional accuracy and slot heights were determined using a scanning electron microscope and an optical scanner. Also, all specimens were analysed using the Geomagic Control X 3D inspection software. The root mean square (RMS) values were used for trueness and precision assessment. Statistical analyses were performed using an independent sample t-test.

RESULTS

Slot height dimensions, trueness RMS, and precision RMS were statistically affected by different AM methods (p < .01). There was a significant difference between the different printing methods, with DLP meeting the tolerance requirements (mean slot height = 0.557 ± 0.018 mm) and MJ being slightly below them (mean slot height = 0.544 ± 0.021 mm). However, MJ significantly outperformed DLP in terms of accuracy. Among the two printing methods, MJ was associated with higher trueness (RMS = 0.025 ± 0.004 mm) and precision (RMS = 0.038 ± 0.005 mm).

CONCLUSIONS

Both tested AM methods yielded clinically acceptable outcomes, with the RMS range set to ±100 μm and the slot height tolerance established at 0.549-0.569 mm. The MJ technology achieved the highest accuracy.

Effect of wall thickness on shape accuracy of hollow zirconia artificial teeth fabricated by a 3D printer

PURPOSE

This study aimed to analyze how the wall thickness of 3D-printed hollow zirconia teeth affects shape accuracy.

METHODS

Datasets with measurement points were created for different artificial teeth resembling the mandibular right first molar (Geomagic Design X, 3D Systems). Reference distances were 9.8 mm for mesio-distal direction (M-D), 10.9 mm for bucco-lingual direction (B-L), 7.0 mm for MB-BB and DB-BB, and 4.5 mm for ML-LB and DL-LB. The outer geometry was identical for all artificial teeth with wall thicknesses of 0.30, 0.50, 0.75, and 1.00 mm. Twenty zirconia teeth were fabricated using a 3D printer (CeraFab 7500 Dental, Lithoz) for each group and sintered before support removal. After performing analog distance measurements using a micrometer screw, the digital distance measurements and angular deviations between measurement points on 3D scans were analyzed. Possible effects were investigated using nonparametric ANOVA, followed by Tukey's honest significant difference (HSD) test for multiple comparisons.

RESULTS

The shape accuracy was acceptable for artificial teeth with wall thicknesses of ≥0.5 mm. The largest distance deviation was observed for a wall thickness of 0.3 mm. In particular, DB-BB showed a median deviation of >56.2 µm, which is significantly larger than that for other test groups, ranging from 7.4-9.5 µm (P < 0.05). In most cases, angular deviations were the largest for teeth with 0.3-mm wall thickness (11.6°) and remained below 5.0° for the other test groups.

CONCLUSIONS

Acceptable accuracy was obtained for artificial teeth with wall thicknesses of at least 0.5 mm.

Fabrication trueness and internal fit of different lithium disilicate ceramics according to post-milling firing and material type

OBJECTIVES

To evaluate whether post-milling firing and material type affect the fabrication trueness and internal fit of lithium disilicate crowns.

METHODS

A prefabricated cobalt chromium abutment was digitized to design a mandibular right first molar crown. This design file was used to fabricate crowns from different lithium disilicate ceramics (nano-lithium disilicate (AM), fully crystallized lithium disilicate (IN), advanced lithium disilicate (TS), and lithium disilicate (EX)) (n = 10). Crowns, the abutment, and the crowns when seated on the abutment were digitized by using an intraoral scanner. Fabrication trueness was assessed by using the root mean square method, while the internal fit was evaluated according to the triple scan method. These processes were repeated after the post-milling firing of AM, TS, and EX. Paired samples t-tests were used to analyze the effect of post-milling firing within AM, TS, and EX, while all materials were compared with 1-way analysis of variance and Tukey HSD tests (α = 0.05).

RESULTS

Post-milling firing reduced the surface deviations and internal gap of AM and EX (P ≤ 0.014). AM mostly had higher deviations and internal gaps than other materials (P ≤ 0.030).

CONCLUSIONS

Post-milling firing increased the trueness and internal fit of tested nano-lithium disilicate and lithium disilicate ceramics. Nano-lithium disilicate mostly had lower trueness and higher internal gap; however, the maximum meaningful differences among tested materials were small. Therefore, the adjustment duration and clinical fit of tested crowns may be similar.

CLINICAL SIGNIFICANCE

Tested lithium disilicate ceramics may be suitable alternatives to one another in terms of fabrication trueness and internal fit, considering the small differences in measured deviations and internal gaps.

Optical properties, biaxial flexural strength, and reliability of new-generation lithium disilicate glass-ceramics after thermal cycling

PURPOSE

To investigate the color stability, translucency, biaxial flexural strength (BFS), and reliability of nano-lithium disilicate and fully crystallized lithium disilicate after thermal cycling and to compare with those of a commonly used lithium disilicate.

MATERIALS AND METHODS

Three lithium disilicate glass-ceramics were used to prepare disk-shaped specimens (ø:12 mm, thickness: 1.2 mm) from A2 shaded HT blocks (Amber Mill, AM; Initial LiSi Block, IN; IPS e.max CAD, EX). AM and EX specimens were crystallized, and all specimens were polished with a polishing paste (Diamond Polish Mint). A spectrophotometer (CM-26d) was used to measure color coordinates before and after thermal cycling. BFS test was performed after thermal cycling. Color differences (ΔE00 ) and relative translucency parameter (RTP) values were calculated. One-way analysis of variance (ANOVA) (ΔE00 and BFS), two-way ANOVA followed by Tukey's HSD tests (RTP), and chi-square tests (Weibull modulus and characteristic strength) were used for the statistical analyses (α = 0.05).

RESULTS

No significant differences were observed among the ΔE00 values of tested materials (df = 2, F = 2.933, p = 0.070). RTP values were only affected by material type (p < 0.001) as AM had the highest RTP (p < 0.001), whereas IN and EX had similar values (p ≥ 0.165). BFS values varied among tested materials (df = 2, F = 21.341, p < 0.001). AM and EX had similar BFS values (p = 0.067) that were higher than that of IN (p ≤ 0.001). Weibull moduli of the materials were similar (p = 0.305), whereas EX had the highest and IN had the lowest characteristic strength values (p < 0.001) CONCLUSIONS: Although nano-lithium disilicate had the highest translucency, all materials had imperceptible color and translucency changes after thermal cycling when reported threshold values were considered. Newly introduced lithium disilicate glass-ceramics had adequate flexural strength as compared to the precursor material.

Comparison of occlusal contact errors of 6 chairside CAD/CAM crowns: a self-controlled clinical study

OBJECTIVES

The purpose of this self-controlled clinical study was to evaluate the trueness of occlusal contacts of chairside CAD/CAM crowns fabricated using different ceramic materials.

MATERIALS AND METHODS

Ten volunteers (8 females, 2 males, average aged 20-30) were recruited in this study registered in the Clinical Trials Registry (#NCT05346744). After tooth preparation on tooth 36 or 46, an optical scan unit (CEREC Omnicam, Sirona Dental Systems, Germany) was utilized to perform the intraoral scanning. For each volunteer, 6 crowns were fabricated via the chairside CAD/CAM process (CEREC, Sirona Dental Systems, Germany) using the following materials: InCoris TZI (ZIR), Celtra Duo (CD), e.max CAD (EMA), UP.CAD (UP), Enamic (ENA) and Hyramic (HY). The microhardness of the milled surfaces was measured through a Vickers hardness Tester (HVS-50Z, Trojan, China). Together with the amount of occlusal adjustment, the occlusal contact trueness at both milling and postprocessing stages were quantitatively analyzed by using a high-precision scanner (ATOS, GOM Technologies, USA) and a reverse engineering software (Geomagic Control, 3D Systems, Rock Hill, SC). The times of chairside occlusal adjustment were also recorded. Data were analyzed by one-way analysis of variance (ANOVA) and ANOVA with randomized block design followed by Bonferroni test (p = 0.05).

RESULTS

Significant differences were found in surface microhardness of the materials tested (CD > EMA ~ UP > ENA > HY > ZIR, p < 0.05). Regarding the occlusal contact trueness at milling stage, ZIR showed the lowest (p < 0.05), while no significant difference was found among others (p > 0.05). At postprocessing stage, except for ENA, the occlusal contact trueness of ZIR was significantly lower than that of others (p < 0.05). As for occlusal adjustment amount, ZIR was lower than CD and ENA (p < 0.05). In addition, ENA, HY and ZIR required fewer times of occlusal adjustment than EMA, UP and CD.

CONCLUSIONS

The type of chairside CAD/CAM ceramic materials affected the occlusal contact trueness throughout the process of manufacturing and the amount of clinical occlusal adjustment as well. Zirconia exhibited the worst occlusal contact trueness at both milling and postprocessing stages, while the amount of occlusal adjustment was the least, which recommended the least occlusal compensation.

CLINICAL RELEVANCE

For better trueness, different negative occlusal offsets are suggested to be applied in the design process, so as to suit the material of the restoration.

A Comparative Study of Additive and Subtractive Manufacturing Techniques for a Zirconia Dental Product: An Analysis of the Manufacturing Accuracy and the Bond Strength of Porcelain to Zirconia

This study was aimed at preparing zirconia samples via additive manufacturing (AM) and subtractive manufacturing (SM) and testing the following aspects: (1) the manufacturing accuracy of the zirconia samples and (2) the bond strength of porcelain to zirconia to evaluate the applicability of the zirconia fabricated by AM in dental clinics. We used three milling machines for SM (AR, K5, and UP) and a 3D printer for AM (AO). The manufacturing accuracy of the zirconia specimen in the internal and marginal areas was evaluated by superimposing techniques to calculate the root mean square (RMS) values. The bond strengths of porcelain to zirconia prepared via SM and AM were measured using a universal testing machine. The internal and marginal RMS values of the zirconia prepared by AM (AO) were within the range of those of the zirconia prepared by SM (AR, K5, and UP). Moreover, the bond strength value of the zirconia prepared by AM (35.12 ± 4.09 MPa) was significantly higher than that of the zirconia prepared by SM (30.26 ± 5.20 MPa). Therefore, AM technology has significant potential for applications in dentistry.

Comparison of the accuracy of resin-composite crowns fabricated by three-dimensional printing and milling methods

This study aimed to compare the dimensional accuracies of three-dimensional (3D)-printed and milled resin-composite crowns, and to determine acceptable abutment-tooth shapes for printing. Four first-molar abutment models were prepared: the master model form and three models with sharp occluso-axial line angles. Crowns were designed on each abutment using computer-aided design software. The drill-offset value was set at 0.0 or 0.5 mm to evaluate the effect on the dimensional accuracy of milling. A digital light processing-based 3D printer was used to fabricate 3D-printed crowns. Milled crowns were fabricated by wet-milling. The trueness was evaluated by superimposing the design data. Regardless of the abutment form, 3D-printed crowns showed higher accuracy with fewer marginal discrepancies than milled crowns. Milled crowns showed significant dimensional deviations, especially at cusps. Moreover, offset correction resulted in grooves on the internal surface of milled crowns with negative deviations, which were especially evident in crowns for the sharp models.

Load-to-Failure Resistance and Optical Characteristics of Nano-Lithium Disilicate Ceramic after Different Aging Processes

The aim of this study was to compare the load-to-failure resistance and optical properties of nano-lithium disilicate (NLD) with lithium disilicate (LDS) and zirconia-reinforced lithium silicate (ZLS) in different aging processes. Thirty crowns were milled from NLD, LDS, and ZLS (n = 10). All crowns were subjected to thermomechanical aging and loaded until catastrophic failure. Ten specimens from each material were prepared in two different thicknesses (0.7 mm and 1.5 mm, n = 5), and color coordinates were measured before and after coffee thermocycling. Color differences (ΔE00) and relative translucency parameter (RTP) were calculated. Data were analyzed by using ANOVA and Bonferroni-corrected t-tests (α = 0.05). ZLS had the highest load-to-failure resistance (p ≤ 0.002), while the difference between LDS and NLD was nonsignificant (p = 0.776). The interaction between material type and thickness affected ΔE00 (p < 0.001). Among the 0.7 mm thick specimens, ZLS had the lowest ΔE00 (p < 0.001). Furthermore, 1.5 mm thick ZLS had lower ΔE00 than that of 1.5 mm thick LDS (p = 0.036). Other than ZLS (p = 0.078), 0.7 mm thick specimens had higher ΔE00 (p < 0.001). The interaction between material type, thickness, and thermocycling affected RTP (p < 0.001). Thinner specimens presented higher RTP (p < 0.001). NLD and LDS had higher RTP than ZLS (p ≤ 0.036). However, 0.7 mm thick specimens had similar RTP after coffee thermocycling (p ≥ 0.265). Coffee thermocycling reduced the RTP values of 0.7 mm thick NLD (p = 0.032) and LDS (p = 0.008). NLD may endure the occlusal forces present in the posterior region. However, long-term coffee consumption may impair the esthetics of restorations particularly when thin NLD is used.

Zirconia-reinforced lithium silicate (ZLS) mechanical and biological properties: A literature review

OBJECTIVES

This paper aimed to provide a literature review of the mechanical and biological properties of zirconia-reinforced lithium silicate glass-ceramics (ZLS) in Computer-aided design / Computer-aided manufacturing (CAD/CAM) systems.

DATA/SOURCES

An extensive search of the literature for papers related to ZLS was made on the databases of PubMed/Medline, Scopus, Embase, Google Scholar, Dynamed, and Open Grey. The papers were selected by 3 independent calibrated reviewers.

STUDY SELECTION

The search strategy produced 937 records. After the removal of duplicates and the exclusion of papers that did not meet the inclusion criteria, 71 papers were included.

CONCLUSIONS

After reviewing the included records, it was found that two types of ZLS (Vita Suprinity PC; Vita Zahnfabrik and Celtra Duo; Dentsply Sirona) are nowadays available on the market for CAD/CAM systems, similar in their chemical composition, microstructure, and biological-mechanical properties. ZLS is reported to be a biocompatible material, whose fracture resistance can withstand physiological chewing loads. The firing process influences the improvements of strength and fatigue failure load, with a volumetric shrinkage. To date, ZLS can be considered a viable alternative to other glass-ceramics for fixed single restorations.

CLINICAL SIGNIFICANCE

. As to biocompatibility and mechanical properties of ZLS, data are still scarce, often controversial and limited to short-term observational periods. These promising ceramics require further in vitro/in vivo studies to accurately define mechanical and biological properties, mainly in the long-term performance of restorations produced with such materials.