A base-line study of the wear of burs used for chairside milling of ceramic crowns of different hardness: effect on internal fit and surface roughness

INTRODUCTION: Wear of milling burs may affect the internal fit and surface roughness of the milled crown. AIM: To assess the wear of diamond and tungsten carbide (TC) burs from milling ceramic materials and the effect on internal fit and surface roughness. METHODS: Thirty crowns of each of the two materials were milled from the same standard preparation. Diamond burs were used for a feldspathic ceramic and TC burs for zirconia. Before and after the 10th, 20th and 30th milling, diamond particle loss was counted and cutting blade changes of the TC burs measured. Internal fit was measured using a silicone replica technique and surface roughness by 3D laser microscope. RESULTS: An average 26% loss of diamond particles occurred after 30 crowns, resulting in a 6% decrease in internal luting space and a 21% decrease in surface roughness. Wear of the TC burs resulted in a 13% decrease in the luting space, and a 16% increase in surface roughness. CONCLUSION: The wear of milling burs reduces the luting space, and the milling parameters must be adjusted to compensate for this. Surface roughness is affected by bur type: with diamond burs it decreased, and increased with TC burs.