Effect of cavity design on the fracture resistance of zirconia onlay ceramics

Abstract

Objective: The purpose of this study was to evaluate the fracture resistance and failure modes of onlay restorations prepared with different preparation designs.

Materials and Methods: A total of 42 extracted, mandibular first molars (36, 46) were used and divided into six groups according to preparation design, as follows 1A: Anatomic preparation of cusps/rounded shoulder margin/occlusal groove; 1B: Flat preparation of cusps/rounded shoulder margin/occlusal groove; 2A: Anatomical preparation of cusps/occlusal groove; 2B: Flat preparation of cusps/occlusal groove; 3A: Complete anatomical reduction of cusps/rounded shoulder margin; 3B: Complete flat reduction of cusps/rounded shoulder margin
groups; intact tooth: No preparation. Onlays were constructed with 0.5‑mm copings of Zirconia ceramic. The copings were veneered with porcelain (IPS e. max Ceram). All samples were subjected to fracture resistance testing. Data were analyzed with Kruskal–Wallis and Bonferroni‑Dunn tests.

Results: Fracture resistance varied significantly according to preparation design. Among the anatomic occlusal preparation designs, fracture resistance was significantly lower in Group 3 when compared to Groups 1 and 2 (P < 0.05). Among the flat occlusal preparation designs, fracture resistance was significantly higher in Group 1 when compared to Groups 2 and 3 (P < 0.05).

Conclusion: Preparation design affected the fracture resistance of onlay restorations. Cavities with flat occlusal preparation designs, a groove and shoulder margins (1B) resulted in the highest fracture resistance, whereas teeth prepared with a complete reduction of cusps and shoulder margins (3A) had the lowest fracture resistance.

Keywords: Fracture resistance, onlay restoration, preparation design, zirconia