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The rehabilitation of free-end situations is a frequent indication in prosthetic dentistry. Cantilever fixed dental prostheses (cFDPs) made of 1st and 2nd generation zirconia are one treatment option. Due to a unique gradient technology, combinations of different zirconium dioxide generations are thus feasible in one restoration. However, data about these materials are rare. The purpose of this study was therefore to investigate the fracture resistance and fracture modes of tooth-supported cFDPs fabricated from different zirconia materials (gradient technology) and different framework thicknesses. A total of 40 cFDPs were fabricated using the CAD/CAM approach and belonged to five test groups. The different groups differed in the yttria content, the proportion of the tetragonal/cubic phases, or in wall thickness (0.7 mm or 1 mm). After completion, the cFDPs were subjected to thermal cycling and chewing simulation (1.2 × 106 load cycles, 108 N load). Afterwards, cFDPs were statically loaded until fracture in a universal testing machine. A non-parametric ANOVA was compiled to determine the possible effects of group membership on fracture resistance. In addition, post-hoc Tukey tests were used for bivariate comparisons. The mean fracture loads under axial load application ranged from 288 to 577 N. ANOVA detected a significant impact of the used material on the fracture resistances (p < 0.001). Therefore, the use of cFDPs fabricated by gradient technology zirconia may not be unreservedly recommended for clinical use, whereas cFPDs made from 3Y-TZP exhibit fracture resistance above possible masticatory loads in the posterior region.

Background: The objective was to determine the optimal connector size and position within zirconia disks for implant-supported cantilever fixed dental prostheses (ICFDP). Methods: Two-unit ICFDPs (n = 60) were designed for the premolar region with connector sizes of either 9 or 12 mm2 and positioned in the enamel or dentin layer of two different types of zirconia disks. The restorations were milled and cemented onto zirconia implants. After simulated chewing for 1.2 Mio cycles, the fracture load was measured and fractures were analyzed. Results: No fractures of ICFDPs or along the implants were detected after simulated aging. The mean fracture load values were significantly higher for a connector size of 9 mm2 (951 N) compared with 12 mm2 (638 N). For the zirconia material with a higher biaxial flexural strength, the fracture load values were increased from 751 to 838 N, but more implant fractures occurred. The position within the zirconia disk did not influence the fracture load. Conclusions: A connector size of 9 mm2 and a zirconia material with a lower strength should be considered when designing ICFDPS on zirconia implants to reduce the risk of fractures along the intraosseous implant portion.

Fit accuracy and fracture strength of milled monolithic zirconia (Zi) and zirconia-reinforced lithium silicate (ZLS) crowns are important parameters determining the success of these restorations. This study aimed to evaluate and compare the marginal and internal fit of monolithic Zi and ZLS crowns, along with the fracture load, with and without mechanical aging. Thirty-two stone dies acquired from a customized master metal molar die were scanned, and ceramic crowns (16 Zi Ceramill Zolid HT+ and 16 ZLS Vita Suprinity) were designed and milled. Absolute marginal discrepancies (AMD), marginal gaps (MG), and internal gaps (IG) of the crowns, in relation to the master metal die, were evaluated using x-ray nanotomography (n = 16). Next, thirty-two metal dies were fabricated based on the master metal die, and crowns (16 Zi; 16 ZLS) cemented and divided into four groups of eight each; eight Zi with mechanical aging (MA), eight Zi without mechanical aging (WMA), eight ZLS (MA), and eight ZLS (WMA). Two groups of crowns (Zi-MA; ZLS-MA) were subjected to 500,000 mechanical cycles (200 ± 50 N, 10 Hz) followed by axial compressive strength testing of all crowns, until failure, and the values were recorded. Independent sample t tests (α = 0.05) revealed no significant differences between Zi and ZLS crowns (p > 0.05); for both internal and marginal gaps, however, there were significant differences in AMD (p < 0.005). Independent samples Mann–Whitney U and Kruskal–Wallis tests revealed significant differences between the two materials, Zi and ZLS, regardless of fatigue loading, and for the individual material groups based on aging (α = 0.05). Multiple comparisons using Bonferroni post-hoc analysis showed significant differences between Zi and ZLS material groups, with or without aging. Within the limitations of this study, the ZLS crown fit was found to be on par with Zi, except for the AMD parameter. As regards fracture resistance, both materials survived the normal range of masticatory forces, but the Zi crowns demonstrated greater resistance to fracture. The monolithic Zi and ZLS crowns seem suitable for clinical application, based on the fit and fracture strength values obtained.

The aim of this study was to investigate the load to fracture and fracture pattern of prosthetic frameworks for tooth-supported fixed partial dentures (FPDs) fabricated with different subtractive computer-aided design and computer-aided manufacturing (CAD-CAM) materials. Materials and Methods: Thirty standardized specimens with two abutments were fabricated to receive three-unit posterior FDP frameworks with an intermediate pontic. Specimens were randomly divided into three groups (n = 10 each) according to the material: group 1 (MM)—milled metal; group 2 (L)—zirconia; and group 3 (P)—Polyetheretherketone (PEEK). The specimens were thermo-cycled and subjected to a three-point bending test until fracture using a universal testing machine (cross-head speed: 1 mm/min). Axial compressive loads were applied at the central fossa of the pontics. Data analysis was made using one-way analysis of variance, Tamhane post hoc test, and Weibull statistics (α = 0.05). Results: Significant differences were observed among the groups for the fracture load (p < 0.0001). MM frameworks showed the highest fracture load values. The PEEK group registered higher fracture load values than zirconia samples. The Weibull statistics corroborated these results. The fracture pattern was different among the groups. Conclusions: Milled metal provided the highest fracture load values, followed by PEEK, and zirconia. However, all tested groups demonstrated clinically acceptable fracture load values higher than 1000 N. PEEK might be considered a promising alternative for posterior FPDs.

In vitro studies investigating the mechanical properties of dental reconstructions use various materials to replicate prepared teeth. However, no uniform recommendation exists as to which material is most suitable for standardized testing. The purpose of this study was to identify a material that resembles human dentin in fracture load tests. Sixteen human teeth were scanned with an intraoral scanner to obtain copies of the original crown morphology and were then prepared for crowns. Replica dies of the prepared teeth including the root morphology were fabricated with a Computer-aided design and computer-aided manufacturing (CAD/CAM) system and divided into four groups: (A) reinforced composite (RC); (B) human dentin (HD); (C) polymethyl methacrylate (PM); and (D) hybrid ceramic (HC). Sixty-four feldspar ceramic crowns were designed with the biocopy mode, fabricated with a CAD/CAM system, luted on the dies, and then with the roots embedded in polymethyl methacrylate. Care was taken to position all specimens of the same morphology identically. Thermo-mechanical load cycling was performed in a chewing simulator followed by fractural loading of the crowns. A mixed effect linear model was fitted to the data, and pairwise contrasts were estimated on the marginal means and corrected for multiple testing according to Tukey (α = 0.05). The means for fracture load (N) were 2435 N (95% CI (2162, 2709)) for hybrid ceramic, 1838 N (95% CI (1565, 2112)) for reinforced composite, 1670 N (95% CI (1396, 1943)) for human tooth and 1142 N (95% CI (868, 1415)) for polymethyl methacrylate abutment materials. Post-hoc pairwise contrasts revealed a statistically significant (p < 0.05) difference among all groups except for reinforced composite and human dentin (p = 0.76). The results indicate that the mechanical properties of abutment dies play a significant role for a possible substitution of natural teeth in in vitro studies.

Various protocols are available to preclinically assess the fracture resistance of zirconia oral implants. The objective of the present review was to determine the impact of different treatments (dynamic loading, hydrothermal aging) and implant features (e.g., material, design or manufacturing) on the fracture resistance of zirconia implants. An electronic screening of two databases (MEDLINE/Pubmed, Embase) was performed. Investigations including > 5 screw-shaped implants providing information to calculate the bending moment at the time point of static loading to fracture were considered. Data was extracted and meta-analyses were conducted using multilevel mixed-effects generalized linear models (GLMs). The Šidák method was used to correct for multiple testing. The initial search resulted in 1864 articles, and finally 19 investigations loading 731 zirconia implants to fracture were analyzed. In general, fracture resistance was affected by the implant design (1-piece > 2-piece, p = 0.004), material (alumina-toughened zirconia/ATZ > yttria-stabilized tetragonal zirconia polycrystal/Y-TZP, p = 0.002) and abutment preparation (untouched > modified/grinded, p < 0.001). In case of 2-piece implants, the amount of dynamic loading cycles prior to static loading (p < 0.001) or anatomical crown supply (p < 0.001) negatively affected the outcome. No impact was found for hydrothermal aging. Heterogeneous findings of the present review highlight the importance of thoroughly and individually evaluating the fracture resistance of every zirconia implant system prior to market release.

The aim of the current investigation was to evaluate the fracture resistance of one-piece zirconia oral implants with and without all-ceramic incisor crowns after long-term thermomechanical cycling. A total of 48 implants were evaluated. The groups with crowns (C, 24 samples) and without crowns (N, 24 samples) were subdivided according to the loading protocol, resulting in three groups of 8 samples each: Group “0” was not exposed to cyclic loading, whereas groups “5” and “10” were loaded with 5 and 10 million chewing cycles, respectively. This resulted in 6 different groups: C0/N0, C5/N5 and C10/N10. Subsequently, all 48 implants were statically loaded to fracture and bending moments were calculated. All implants survived the artificial aging. For the static loading the following average bending moments were calculated: C0: 326 Ncm; C5: 339 Ncm; C10: 369 Ncm; N0: 339 Ncm; N5: 398 Ncm and N10: 355 Ncm. To a certain extent, thermomechanical cycling resulted in an increase of fracture resistance which did not prove to be statistically significant. Regarding its fracture resistance, the evaluated ceramic implant system made of Y-TZP seems to be able to resist physiological chewing forces long-term. Restauration with all-ceramic single crowns showed no negative influence on fracture resistance.