Adaptation and uniformity of monolithic zirconia crowns fabricated by additive 3-dimensional gel deposition

A novel monolithic zirconia restoration fabricated by additive 3-dimensional (3D) gel deposition, named as self-glazed zirconia (SGZ), has recently been developed. SGZ crowns exhibit reliable mechanical properties and esthetic appearance, but their adaptation and uniformity are unclear.The purpose of this in vitro study was to compare the adaptation and uniformity of monolithic zirconia crowns fabricated by additive 3D gel deposition with that of milled zirconia and lithium disilicate crowns.Ten identical resin abutments were made based on the scanning data of an extracted and prepared human mandibular first molar. Three types of monolithic crowns were then fabricated by using 2 different processes: 3D gel deposition zirconia (SGZ), milled zirconia (ZZ), and milled lithium disilicate (EMX) (n=10) through a completely digital workflow. The nondestructive direct-view technique and replica technique were used to measure the marginal and internal discrepancy values individually. The uniformity index was calculated to describe the uniformity of the internal space. The results were analyzed by using 1-way ANOVA and Kruskal-Wallis statistical tests (α=.05).The marginal discrepancy of EMX exhibited the highest values among the 3 groups (P=.001). The 2 types of zirconia crowns had comparable marginal discrepancy values (P>.05). The internal discrepancy values of SGZ were significantly lower than those of EMX at the occlusal region and of ZZ at all measured locations (P<.05). All 3 types of monolithic crowns showed comparable good uniformity (P=.056).The marginal and internal adaptations of novel monolithic zirconia crowns were within clinical requirements. Compared with the zirconia and lithium disilicate crowns fabricated by subtractive milling, monolithic zirconia crowns fabricated by additive 3D gel deposition had comparable uniformity and better internal adaptation.