Zirconia Restorations:: Evolution and Innovation

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ZIRCONIA

R E S TO R AT I O N S :
EVOLUTION
A N D I N N O VAT I O N
By Dennis J. Fasbinder, D.D.S.
Z I R C O N I A R E S T O R AT I O N S : E V O L U T I O N A N D I N N O VAT I O N

CONTENTS
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25

A L L C O N T E N T S © 2 0 2 0 S P E A R E D U C AT I O N
Introduction

Zirconia Mircostructure

Monolithic Restorations

Strength

Esthetics

Zirconia Surface Wear

Conclusion

References

About the Author

About Spear
INTRODUCTION
Interest in ceramic materials has While there is a wide range of
continued to increase over the past material options available for crowns,
few decades as higher strength a survey of more than 1,700 dentists
ceramics have afforded expanded in the National Dental Practice-Based
clinical applications. Optimal goals Research Network indicated that
for ceramic materials would be monolithic zirconia is the most
to deliver superior esthetics, common choice of material for a
with predictable, cost effective posterior crown. (Makhija et al 2016)
fabrication, and long-term durability. Several factors were suggested as
influencing the shift toward monolithic
Glass ceramic materials have zirconia crowns, including increased
consistently provided enamel-like patient demand for esthetic
appearance; however, they are also restorations, the cost effectiveness
brittle materials. Clinical research of zirconia, and that zirconia has
has consistently reported that the significantly greater strength than
primary failure mechanism of glass glass ceramic materials and offers the
ceramics is chipping and fracture. additional advantage of allowing for
(Pjetursson, 2007) more conservative tooth preparations.

Zirconia was initially introduced for


clinical use as a more esthetic core
material compared to metal. Early
zirconia crowns were veneered with
feldspathic porcelain to improve the
esthetic appearance of the crown
because zirconia is relatively opaque
with a higher value. However, the
chipping of the veneer porcelain led
many dentists to be discouraged with
its use. One meta-analysis of single
crowns with a zirconia core reported
a 91.2% survival rate, which was
significantly lower than that of
metal-ceramic crowns at five years.
(Sailer 2015)
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Full-contour, monolithic zirconia While zirconia is often presented


crowns are preferred due to the as a single material, different
simple fact that the surface of a formulations have evolved with
full-contour zirconia crown is considerably different polycrystalline
resistant to chipping or fracture. structures and physical properties.
(Lawson, Burgess 2014) They An understanding of the various
also exhibit high flexural strength, types of zirconia materials will aid
allow for more conservative dental in making informed clinical decisions
preparation, and minimize wear to to promote the desired clinical
antagonist dentition. (Albashaireh, outcome for the case.
2010; Grin, 2013)

5
ZIRCONIA MICROSTRUCTURE

Zirconium is a soft, silver-colored Zirconia is referred to as metastable


metal recovered as a mineral called since it can occur in three different
Zircon (ZrSiO4). It is mined primarily crystalline phases depending on
from large deposits in Australia and temperature and pressure parameters.
South Africa and shipped to plants (Zhang 2018) Zirconia exists in the
for processing. The mined Zircon is monoclinic phase in its naturally
purified, and metal oxides are added to occurring state at room temperature
the refined powder such as yttrium to and pressure. A uniform monoclinic
stabilize the metastable crystal form, zirconia would not be of use in dentistry
aluminum to prevent water corrosion, since it has poor strength properties.
and other coloring components. The At an elevated temperature of ~1170° C
Tosoh Corporation in Japan supplies the monoclinic phase transforms into
the vast majority of the raw zirconia the tetragonal phase.
powders for dental manufacturers. So
essentially almost all dental zirconia The tetragonal phase can be stabilized
materials are fabricated from the same at room temperatures by adding small
zirconia raw material. (Helvey 2017) amounts of additives, called dopants,
to the zirconia. Yttria has become the
Zirconia is a polycrystalline material most effective dopant in amounts
that does not contain glass particles of 3 weight% to 5 weight% that is
even though it is commonly described equivalent to 3 mol%. The third phase
as a “ceramic” material. Although the of zirconia transforms at temperatures
various brands of zirconia may be above 2,300° C into the cubic phase. A
manufactured from the same raw greater amount of yttria is required to
zirconia powder, the quality and stabilize it (> 9.3 weight%) at room
properties of a specific brand of zirconia temperature resulting in compositions
are a function of the processing of the 5 mol% (about 50% cubic phase).
raw materials by the manufacturer to (Helvey 2017)
minimize porosity, enhance density,
and ensure a homogenous material. Compared with other dental ceramics,
3 mol% zirconia has higher flexural
strength, fracture toughness, and
hardness, mainly derived from the
mechanism called “transformation
toughening.” (Pittayachawan 2009)
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The tetragonal phase accounts for the It generally requires a porcelain veneer
high strength properties of 3 mol% to create the desired esthetic outcomes.
zirconia. As a result of externally applied Examples of these include: Lava
stresses, such as a crack initiation, the Zirconia (3M), BruxZir (Glidewell), Cercon
energy at the leading edge of the crack (Dentsply Sirona), and IPS e.max ZirCAD
causes the tetragonal crystals to locally MT (Ivoclar Vivadent). (Zhang 2018)
phase shift to monoclinic crystals.
The challenge for manufacturers of 3
The monoclinic crystals are volumetrically mol% zirconia was to improve the
larger than the tetragonal crystals and esthetic appearance of the material
this expansion results in a localized while maintaining the desired high
compressive force applied to the leading strength properties. This fostered the
edge of the crack. The compressive introduction of “anterior zirconia” or
forces essentially prevent the crack “translucent zirconia.” Development
from propagating. This t > m of translucent zirconia has included
transformation, or transformation techniques such as increasing the
toughening, is a major contributor to amount of yttria, reducing the c
the high strength of zirconia and its oncentration of alumina, eliminating
ability to resist fracture under loading. porosity by sintering at higher
temperatures, reducing the crystalline
While the term “full contour zirconia” grain size, and increasing the amount
is often used to describe a monolithic, of cubic phase in the material.
high strength, tooth-colored material, (Zhang 2018)
there is considerable variation in
zirconia. The original zirconia materials
introduced prior to ~2014 were 3 mol%
that were 90%-100% tetragonal
polycrystals and had very high strength
The challenge for manufacturers
properties. However, it tends to be
relatively opaque, with a high value, of 3 mol% zirconia was to improve
and less esthetic than glass ceramics
the esthetic appearance of the
for matching natural tooth structure.
material while maintaining the
desired high strength properties.

7
Two early initiatives to improve
translucency of these materials were
to significantly reduce the amount
of alumina dopant added and
reducing porosity by sintering
at higher temperatures. These
improvements paved the way for
monolithic full-contour zirconia
restorations. Material examples of
this were Lava Plus (3M), Vita YZ
HT (Vita), BruxZir Full Strength
(Glidewell), Katana HT/ML (Kuraray
Noritake), and InCoris TZI (Dentsply
Sirona). (Zhang 2018)

This modest improvement in the


appearance of zirconia still limited
its application in full contour
restorations to posterior teeth with
lower esthetic demands.

Figures 1-3: CEREC zirconia crowns (3 mol%)


delivered for teeth #19 and #20.
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The most recent attempt to increase


the translucency of zirconia is to
significantly increase the cubic
crystalline phase to >25% and stabilize
it with 5 mol% yttria. (McLaren 2017)
The cubic crystalline phase decreases
light scattering that occurs at grain
boundaries and the zirconia appears
more translucent.

However, this approach also reduces


the flexural strength and fracture
toughness because stabilized cubic
zirconia does not transform at room
temperature. (Zhang 2016) This results
in a 35%-40% reduction of the flexural
strength compared to 3 mol% zirconia.
Recently introduced zirconia of this
type include Lava Esthetic (3M), Katana
Zirconia UTML/STML (Kuraray
Noritake), BruxZir Anterior (Glidewell
Laboratories), and ArgenZ Anterior
(Argen Corp.). (Zhang 2016, McLaren
et al 2017)

Figures 4-6: Pre-operative #3 with stained, caries under ceramic


crown replaced with full contour polished Katana zirconia crown
(5 mol%).

9
As the composition of zirconia At this point, one may be thinking
materials has evolved, it can be helpful that this may be more information on
to consider some sort of general zirconia structure than really needed.
classification system to provide a basis This categorization obviously reveals
to understand differences in materials. the changing physical properties of
One simple categorization of zirconia different types of zirconia is directly
materials is based on the mol% of related due to the different proportions
yttria. (Burgess 2018) 3 mol% zirconia of the polycrystalline phase. There can
are the early zirconia materials that be considerable variation in material
are 85-90% tetragonal phase with properties within each category as
flexural strengths in excess of 1100 yttria is actually measured in tenths
MPa. They are also relatively opaque of a mole percent.
with a high value that limits the
esthetic applications. However, the trend in improving the
translucency of the zirconia is evident
4 mol% zirconia has about 25% cubic moving from 3 mol% to 5 mol%. A
phase with improved translucency similar trend is also noted in the
and flexural strengths in the 750-900 decreasing physical strength properties
MPa range. 5 mol% zirconia has about from 3 mol% to 5 mol% zirconia.
50% cubic phase with significantly
increased translucency. The flexural
strength is further decreased to the
650-800 MPa range.

The changing physical properties of different


types of zirconia is directly related due to the
different proportions of the polycrystalline phase
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M O N O L I T H I C R E S T O R AT I O N S

The primary advantage of early zirconia Zirconia restorations are fabricated


materials was superior strength with a CAD/CAM process regardless
compared to other restorative of the impression technique used to
materials. However, the high value record the tooth preparation. Zirconia
and relative opaque appearance of blanks (pucks or blocks) are available
3 mol% zirconia did not offer the from manufacturers in a partially fired
esthetic appearance required for more or pre-sintered state. This allows for
anteriorly positioned restorations. easier machining of the volume shape
of the computer designed restoration
Bilayer restorations consisting of a high with very good margin fidelity. A
strength, relatively opaque zirconia post-machining oven sintering process
core with a more translucent porcelain at very high temperature, ~1,350° C to
veneer became preferred for improved 1,500° C, is required to fully sinter the
esthetic results. But clinical research zirconia. The oven sintering process
has reported that the chipping/ results in a volumetric shrinkage of
fracture of the veneering porcelain is zirconia between 21% and 24%.
a significant problem. (Sailer 2015)
The introduction of translucent Manufacturers bar code the zirconia
zirconia materials offered an blanks to record the specific
opportunity for monolithic esthetic shrinkage percentage of the blank.
restorations and avoid the potential The bar code is input to the design
for surface chipping/fracture of software to mathematically expand the
veneered zirconia crowns. (Lawson, design by the blank shrinkage factor.
Burgess 2014) The milled restoration is obviously
considerably larger than the desired
final restoration. The milled restoration
volumetrically shrinks to the correct
volumetric size during oven sintering
to create the fully crystallized
zirconia restoration.
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STRENGTH

Material strength is often compared The strength of the ceramic material is


by flexural strength and fracture often cited as a critical element in the
toughness as it may be rationalized success of the restoration. A laboratory
that higher strength may reduce the study illustrates an important point
potential for chipping and fracture. The about material strength. (Nakamura
veneering porcelain on the surface of 2015) The minimum occlusal reduction
porcelain fused to metal (PFM) crowns for 3 mol% zirconia is generally 1.0
has a flexural strength in the range of mm and for 4 mol% zirconia 1.2-1.5
90-100 MPa. mm thick due to the reduced flexural
strength. The fracture rate of
High strength ceramics such as lithium monolithic zirconia crowns (Lava Plus)
disilicate or zirconia-reinforced lithium were compared to lithium disilicate
silicates have flexural strengths in the crowns (e. max Press) at different axial
range of 350-475 MPa with a fracture (0.5, 0.7, and 1.0 mm) and occlusal
toughness of 3.2 to 3.5 MPa/m2. thicknesses (0.5, 1.0, and 1.5 mm).
Zirconia (3 mol%) has a flexural
strength in excess of 900 MPa and a Axial reduction did not significantly
fracture toughness of 5.5 to 7.4 MPa/ influence the fracture rate of either
m2. The significant increase in strength type of crown. However, there was a
of zirconia is perceived to be an significant difference in the strength
advantage for longevity, however of the monolithic zirconia crowns
this still needs to be supported by based on the occlusal thickness.
long-term clinical evidence. Reducing the occlusal thickness of
the crowns resulted in a significant
decrease in fracture resistance. This
illustrates that one must consider the
minimum thickness or volume of
material required to maintain the
desired strength of a material.
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In essence, strength is a conditional While the small sample size from each
property, meaning it depends on an dental laboratory was not statistically
adequate thickness or volume to have significant, the results lend credence
the reported strength. Use of the to the importance of material and
material without regard to its processing relative to expected
recommended dimensional thickness strengths of zirconia materials.
does not ensure the expected level of
material strength and may compromise
the clinical outcome.

A study done by investigators at the Strength is a conditional


American Dental Association compared
the flexural strengths of zirconia from property, meaning it
dental laboratories. (Liao 2018) Dental depends on an adequate
laboratories were asked to submit two
zirconia samples. One sample was thickness or volume to have
of the laboratory’s anterior (high the reported strength
translucency) zirconia and one sample
from the laboratory’s posterior (low
translucency) zirconia.

Posterior zirconia samples had a mean


flexural strength of 492 + 199 MPa and
anterior zirconia samples had a mean
flexural strength of 563 + 136 MPa. The
authors speculated that the variation
in flexural strengths was due to
differences in zirconia materials,
differences in processing techniques
or a combination of both.

15
ESTHETICS

The translucency of a material is an Light scattering occurs as it passes


important contributor to its potential through a material and it changes
esthetic applications. direction. This may be caused by
impurities, defects, different crystalline
When light strikes a polycrystalline phases, and grain boundaries. To make
material (zirconia), a portion of the monolithic zirconia more translucent
light is reflected away from the and aesthetic, the light scattering from
surface, a portion is transmitted the zirconia must be significantly
through the material, and a portion is eliminated. (Kontonaski 2019)
scattered or absorbed into the bulk
of the material. The amount of light One disadvantage of 3 mol% zirconia
that is transmitted is a measure of is that the larger grain size of the
translucency and is related to the tetragonal crystalline particles leads
reflectivity of the surface with to greater light scattering and less
smoother surfaces reflecting more translucency. (Sulaiman 2015) The
light. It is also related to how much lack of translucency also limits 3 mol%
light is scattered as it passes through zirconia chameleon effect of absorbing
the material with more scattering surrounding tooth color as well as more
causing a more opaque appearance. translucent glass ceramic restorations.

The increased zirconia opacity also


lends a brighter appearance to the
zirconia crown. It can be somewhat
problematic to decrease the value of
the crown with surface stains and glaze.
And the increased opacity of the
zirconia also prevents the cement color
from influencing the final shade of
the crown. The addition of a higher
proportion of cubic crystalline phase
in translucent or anterior zirconia
(5 mol%) effectively reduces the grain
sizes and decreased scattering of the
light, which allows more light to be
transmitted, improving the translucency.
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Translucency of ceramic materials has These results are consistent with the
been well documented in laboratory general perception that zirconia is
studies. One study measured the a more opaque material than glass
translucency of zirconia core materials ceramics at the same thickness. But
compared to lithium disilicate ceramic ceramic materials are recommended
in equal thicknesses. The translucency to be 1.5 mm thick occlusally while
of zirconia copings was significantly zirconia materials are recommended to
less than that of the lithium disilicate be 1.0 mm thick occlusally. The authors
glass-ceramic control as one would noted that at clinically recommended
expect of 3 mol% zirconia. thicknesses, the translucency parameters
(Balidissar 2010) of the translucent zirconia materials
were not only similar to those of the
A more recent study compared the lithium disilicate ceramic material but
translucency of lithium disilicate also comparable to the translucency
ceramic (IPS e.max CAD HT) to four parameters reported for 1.0 mm of
different high translucency zirconia in dentin or enamel.
0.5 mm, 1.0 mm, 1.5 mm, and 2.0 mm
thick specimens. (Church 2017) Lithium
disilicate had significantly higher
translucency than translucent zirconia
materials at similar thickness. The
translucencies of the zirconia materials
were fairly similar at each thickness,
however translucency significantly
decreased for each zirconia material
at each increase in thickness.

Light scattering occurs as it passes


through a material and it changes
direction. This may be caused by
impurities, defects, different crystalline
phases, and grain boundaries.

17
Z I R C O N I A S U R FA C E W E A R

Occlusal surface wear is often There are several points of view as to


perceived as a function of material the optimum technique to create a
hardness. Basically, the harder the smooth zirconia restoration. Oven
material, the greater the opposing firing a ceramic glaze to the zirconia
abrasive wear potential. Zirconia is may create a smooth surface since
a very hard material that has been the ceramic glaze will flow across the
thought to be very abrasive to valleys of a rough surface, self-leveling
opposing tooth structure. However, into a smooth surface once it is fired.
wear is actually a function of material However, the glass-containing glaze
smoothness. (Miyazaki 2013) is a thin layer of about 100 microns
and will wear over time in function.
Any material surface magnified enough This would expose a potentially rough
will appear as a series of peaks and surface of the zirconia, possibly
valleys rather than a mirror-like surface. leading to abrasive wear of the
The peaks act as abrasive areas for opposing dentition.
the opposing dentition. The smoother
the material surface, fewer peaks as it For this reason, it has been
were, the less abrasive wear against recommended to polish the occlusal
the opposing dentition. The clinical surface of the zirconia prior to
goal for zirconia would be to create glazing it. This would remove the
a smooth surface to prevent abrasive peaks and valleys and maintain the
wear of the opposing dentition. smooth surface in spite of the wear
of the glass-containing glaze layer.
Polishing proximal surfaces may not
be as critical due to the lack of
functional wear on these areas.
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A second point of view holds that A second aspect of the surface finishing
even if the surface of the zirconia is is concerning an occlusal adjustment of
polished, it will also wear, resulting in a zirconia crown post-cementation. Any
the same surface profile as if the glaze adjustment to the occlusal surface of
were applied and degraded during the zirconia must be repolished to
function. However, zirconia is relatively return the smooth surface to the
resistant to wear due to its high restoration. Failure to do so may result
fracture toughness. in abrasive wear of the opposing
dentition. (Sabrah 2013, Chong 2015)
Surface wear of materials generally
involve some degree of degradation Most of the evidence for the wear
of the material as it is slowly worn caused by zirconia is a result of
down through microfractures of the laboratory studies with simulated
material surface. Zirconia has a high occlusal function systems. One recent
fracture toughness, preventing these systematic review of clinical studies
microfractures of the surface, and related to the antagonist enamel wear
thereby maintaining its rough and of monolithic zirconia posterior crowns
potentially abrasive surface once the included five clinical studies after review
glaze has been worn away. of 198 potential publications. (Gou 2019)

Laboratory studies have demonstrated The results reported by these studies


that polished monolithic zirconia varied widely but in general the
has the least abrasive surface and antagonist wear due to zirconia was
sandblasted and glazed zirconia similar to that of natural teeth and less
causes the highest functional abrasion than that of metal-ceramics. Additional
of the opposing enamel. (Stawarczyk long-term clinical research is needed
2013, Mitov 2012) Additional studies to confirm these findings for newer
have reported that polished monolithic translucent zirconia.
zirconia is less abrasive compared to
classic veneering ceramic (Jung 2010,
Park 2014) or lithium disilicate.
(Rosentritt 2012)

19
CONCLUSION
The evolution of full contour zirconia
illustrates the continued effort to
improve the material for expanding
clinical applications. The high strength
properties of the initial 3 mol% zirconia
are very desirable to clinicians since it
prevents the most common failure of
glass ceramics: chipping and fracture.

It may be an advantage in high-stress


clinical situations with potentially limited
inter-arch space to create the occlusal
reduction required for glass ceramic
restorations. However, the esthetic
properties required improvement. Newer
zirconia materials continue to improve
the translucency and esthetic outcomes.
However, it is also obvious that there
is a significant difference in the
ensuing physical properties of newer
zirconia formulations.

Physical properties and laboratory


studies do not provide sufficient evidence
of clinical success. But the differences
in physical property values between 3
mol%, 4 mol%, and 5 mol% zirconia offer
reasonable evidence that they should
not be considered equivalent materials.
Clinical evidence needs to be collected
to provide insight as to the optimum
applications of these materials.
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ABOUT THE

AUTHOR
Dr. Fasbinder is currently the Director
of the Computerised Dentistry
Program and a clinical professor
in the Department of Cardiology,
Restorative Sciences and Endodontics,
University of Michigan, School of
Dentistry. He is board certified in
general dentistry and maintains a
part-time private practice in Ann
Arbor, Michigan.

Dr. Fasbinder directs the Computerised


Dentistry Unit at the University of
Michigan School of Dentistry that is
dedicated to research and education
on CAD/CAM dental systems. The
CompuDent Unit has been a leader in
Dennis J. Fasbinder, D.D.S.
education and research with the
chairside CAD/CAM systems and
digital impression systems since 1993
resulting innumerous publications.
Dr. Fasbinder is a frequent speaker on
ceramic-based dentistry and digital
dental systems at meetings and
conferences in North America
and abroad.
Based in Scottsdale, Arizona, Spear Education is an innovative dental education
company that includes the following practice-building, member-based services:

Spear Online
The “Gateway to Great Dentistry” includes more than 1,500 video lessons spanning
restorative, esthetics, occlusion, worn dentition, treatment planning and more. But
access is not only for dentist continuing education. Membership provides the entire
office team with staff training, team meeting and patient communication tools — like
the Patient Education platform and native apps, in addition to “Conversation
Essentials” video vignettes — to align the entire practice on patient care.

Spear Study Club


Involves small groups of peers that meet locally as many as eight times a year to
collaborate on real-world cases, improve their clinical expertise and discuss growing
practice profitability. Spear has the largest network of study clubs, with active clubs in
more than 40 states and six countries.

Spear Masters Program Specialist Workshops


With 2½-day workshops for both endodontists and surgical specialists tailored to
meet the needs of doctors and their teams, you will learn how to strengthen
relationships with your referring practices, develop your team for growth and build
the leadership skills necessary to streamline case flow.

Spear Practice Solutions


The technology-enabled business and clinical solutions platform blends custom
education, personalized coaching and real-time analytics to help your practice reach
its full potential.

Spear Campus
Thousands of dentists visit Spear’s scenic Scottsdale campus annually for seminars
and workshops. Members attend sessions in a state-of-the-art, 300-person lecture
hall and receive hands-on training in Spear labs.

Spear Faculty Club


Designed as a prestigious community of doctors who share the journey to Great
Dentistry with others. While all Faculty Club members demonstrate a commitment
to continued learning, professional growth and providing the best patient care, many
also serve as Visiting Faculty and mentor attendees during campus seminars
and workshops.

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