3D printing and milling accuracy influence full-contour zirconia crown adaptation

To correlate trueness and cement-space characteristics of crowns milled chairside and in the laboratory with those of inkjet 3D-printed crowns, and to assess whether 3D-printing accuracy meets the clinical standard.Thirty crowns were either (1) milled using a chairside Cerec MCXL unit from Cerec Zirconia Mono L (Dentsply Sirona), (2) milled using a LX-O 5-axis (Matsuura Machinery) industrial machine from Initial Zirconia HT (GC), or (3) 3D-printed using an inkjet Carmel 1400 (Xjet) printer (n = 10). Crown trueness determined by comparing the original CAD with each visible-light digitized crown was correlated with the 3D cement-space characteristics recorded by micro-CT. Statistics involved Kruskal-Wallis testing and Spearman correlation.Crown trueness at the intaglio marginal area positively correlated with the marginal and axial cement-space characteristics. 3D-printing revealed data in-between those of the two milling systems with undercut values being not statistically different from those recorded for chairside milling and a low overcut level that was statistically similar to that obtained by laboratory milling. Laboratory milling revealed a significantly better marginal accuracy with a consequently lower cement-space thickness. A higher overcut level was recorded for the chairside-milled crowns in the marginal/occlusal thirds, resulting in the significantly highest occlusal cement-space thickness and cement-volume percentage with a cement thickness above 120 µm (limit considered as clinically acceptable). No statistical difference in trueness was found for the external crown dimensions.The 3D-printed zirconia crowns provided sufficient manufacturing accuracy for clinical use. Accurate milling and printing of the crown's intaglio marginal area is primordial.