Zirconia ceramics are increasingly being used for dental prostheses. In the past, they were used as a substructure that was baked with porcelain; nowadays, monolithic zirconia prostheses have been made possible by the introduction of aesthetic zirconia ceramics varieties. They are used more and more, even as RBFDPs (Resin Bonded Fixed Dental Prosthesis).

There is currently quite a lot of discussion about zirconia. So much the better, because it keeps the dynamics of the subject alive. Is it possible to adhesively cement zirconia? Is it permissible to sandblast zirconia? Is it feasible to polish zirconia? Is wear of the antagonist an issue? And so on and so forth.

New dental technologies and materials have been developed in recent years to meet the demand for aesthetic, biocompatible and metal-free prostheses. Although porcelain has been used as an aesthetic dental material for more than hundred years, its restrictions are now well-known. It is the fragility of porcelain (low flexural strength and fracture toughness) in particular which restricts its application in areas where the exertion of massive force on the material is a factor. Zirconia has a high flexural strength and is therefore suitable for multiple dental applications.

Development

The first generation of zirconias used in dentistry belonged to the Partially Stabilised Zirconia (PSZ) class. This type of zirconia, stabilised with yttrium oxide, was composed of a mix of monoclinic, tetragonal and cubic crystals but is no longer used nowadays. The so-called Y-TZP variant was then used for many years, and still is. Its main characteristics are high flexural strength (> 1.000 MPa) and an opaque white appearance. For the most part, this variant is composed of tetragonal crystals of a few hundred nanometers. To keep the material stable at room temperature, approximately 3 mol% of yttrium oxide is added to the composition, which is why it is sometimes referred to as 3Y zirconia.

In order to improve its aesthetic properties, a start was made on the development of a new variety, so-called cubic zirconia. Cubic zirconia is characterised by a high translucence, meaning that a lower flexural strength must be accepted. Admittedly, the flexural strength of this variant is lower than that of the tetragonal variety, but still much higher than the flexural strength of lithium disilicate. It also contains more yttrium oxide; approximately 5 mol%.

Crystal phases

We currently know zirconia crystals in three varieties: monoclinic, tetragonal and cubic. In general, zirconia only exists in the monoclinic phase at room temperature. Monoclinic zirconia has low strength as well as low translucence. Tetragonal zirconia crystals are metastable and can only exist at room temperature after having been stabilised with yttrium oxide, among other metal oxides. The characteristics of tetragonal zirconia are that it is strong, but at the same time devoid of aesthetic
properties. Cubic crystals are stable and ensure improved translucence. Although prostheses made from cubic zirconia are not as strong as the tetragonal variety, they are highly aesthetic, and are even suitable for monolithic restorations in the aesthetic zones.

Multilayer

KATANA™ Zirconia ML, STML and UTML, as well as the latest KATANA™ Zirconia Block, are so-called multilayer zirconias. These products are built up of four layers with an ascending degree of translucency, ranging from the more opaque and coloured body layer (cervical), through two transitional layers, to the translucent incisal edge (occlusal/incisal). The invisible transition from one layer to another is achieved using a unique process. The secret is in the specific distribution of particles during the pre-sintered stage (continuous gap grading). In combination with the cold isostatic pressing method, this ensures material of an outstandingly high quality.

KATANA™ Zirconia Block

The use of KATANA™ Zirconia Block makes it possible to produce a complete monolithic zirconia prosthesis in a short time. This block was developed to be used within the CEREC workflow. After scanning, the prosthesis is ground for approximately 15 minutes and can then be sintered in the SpeedFire oven in just half an hour¹). KATANA™ Zirconia Block shares the properties of KATANA™ STML and can be used for the production of single-unit prostheses such as full crowns for both anterior and posterior applications.

Wear of the antagonist

The question of whether zirconia prostheses are harmful to the antagonist would seem to be justified; after all, this is a very hard material. Hardness, however, does not relate directly to the abrasive properties of a material. Smoothly polished zirconia is minimally abrasive, something which has been corroborated by multiple studies²). Glaze, porcelain, lithium disilicate and even enamel are all more abrasive for the antagonist.

CAD/CAM

Thanks to emerging digital solutions (CAD/CAM) combined with the possibility of executing fixed partial dentures (FPDs) in monolithic zirconia, a fully digital workflow - from scan to prosthesis - is now feasible.

Sandblasting

Sandblasting using alumina is the standard method for the roughening of zirconia. In order to reduce the decline from the tetragonal crystal stage to the monoclinic stage, it is recommended that sandblasting be carried out at a maximum pressure of 2.5 bar using 50 micron aluminium oxide particles as a maximum³). In practice, zirconia is also frequently sandblasted tribochemically, for example, by means of CoJet (3M). The results achieved with this method are variable. In the case of limited pressure (2.5 bar as a maximum) there is a risk that the energy will be insufficient to achieve an effective and complete fusion between the silica and the zirconia surface. It is therefore recommended that CLEARFIL™ Ceramic Primer Plus be used for adhesive connection with the sandblasted surface. The silane in this ceramic primer bonds chemically with the silica, while the MDP bonds with the areas of zirconia not covered by silica. The use of silane alone does not provide an adequate basis for a reliable result⁴). Sandblasting with alumina, however, followed by priming with CLEARFIL™ Ceramic Primer Plus, is a well-proven and reliable method to ensure effective bonding to zirconia⁵).

Not etchable, but certainly bondable

Zirconia is not – or is barely – etchable with the etching technology available (HF). In addition, it cannot be recommended that zirconia be treated with phosphoric acid, because of the bonding of phosphates to the surface of the zirconia, which will inhibit a chemical activation of the surface for some adhesive cementation systems. The question of whether an etching product should be used is a valid one; after all, chemical etching is not necessary to achieve surface roughness. Achieving surface roughness is, however, a logical option, and roughening by means of sandblasting would seem to be the most appropriate method for zirconia. Thereafter, chemical bonding is ensured using a phosphoric functional monomer, preferably MDP.

Adhesion principles

Three basic factors are required to achieve the effective bonding of different materials. In keeping with the principles of adhesion, these are: surface enlargement (micromechanical retention), chemical activity (adsorption and electrostatic bonding) and a high-energetic surface to guarantee proper adaptation.

Adhesive bonding

The best method of adhesive bonding for zirconia is the use of a composite cement containing MDP. Professor Mathias Kern published an article about bonding to zirconia using MDP as early as 1998. This study showed that sustainable resin bonding to zirconia can only be achieved using a composite cement with a special adhesive monomer. The monomer used was in fact MDP. In the meantime, many studies have been published about bonding to zirconia.

On the one hand, these studies concern bonding with phosphate monomers (MDP); on the other hand, attention has been paid to the modification of the zirconia surface to render it etchable. The simplest and most reliable method is to sandblast the surface at a low pressure using aluminium oxide, followed by priming with an MDP-containing primer⁶).

PETER SCHOUTEN,
Technical Manager Kuraray Europe Benelux

1) Depending on the method of grinding/milling.
2) Mörmann W.H. et al. Wear characteristics of current aesthetic dental restorative CAD/CAM materials: Two body wear, gloss retention, roughness and Martens hardness. Journal of the mech. Behavior of Biomedical Materials 20 (2013) 113-125, Janyavula S. et al. The wear of polished and glazed zirconia against enamel. J Prosthet Dent 2013; 109;22-29 Stawarczyk B. et al. Comparison of four monolithic zirconia materials with conventional ones: Contrast ratio, grain size, four-point flexural strength and two-body wear. Journal of the mech. Behavior of Biomedical Materials 59 (2016) 128-138 D’Arcangelo C. et al. Wear Evaluation of Prosthetic Materials Opposing Themselves. Oper Dent 2017 antagonistic surface roughness on the wear of human enamel and nanofilled composite resin artificial teeth. J Prosthet dent 2009; 101: 342-349.
3) Attia A. / Kern M. Effect of cleaning methods after reduced-pressure Air Abrasion on Bonding to Zirconia Ceramic J Adhes Dent 2011; 13: 561-567.
4) Pilo R. Effect of tribochemical treatments and silane reactivity on resin bonding to zirconia. Dent Mater (2017).
5) Kern M. Bonding to oxide ceramics - Laboratory testing versus clinical outcomes. Dent Mater (2014).
6) M. Kern et al., Bonding to zirconia ceramic: adhesion methods and their durability. Dent Mater 14: 64-71, Jan.1998.

Did you know that a complete removal of temporary cement from the abutment tooth with a rubber cup and pumice paste or an ultrasonic scaler is usually impossible? In most cases, some visibly undetectable residues remain on the surface. They will negatively affect the bonding performance of the permanent cementation system you selected. KATANA™ Cleaner is our answer to this problem! Applied after conventional temporary cement removal, it provides optimal conditions for permanent cementation.

All relevant details are revealed in this scientific report.

Did you know that a complete removal of temporary cement from the abutment tooth with a rubber cup and pumice paste or an ultrasonic scaler is usually impossible? In most cases, some visibly undetectable residues remain on the surface. They will negatively affect the bonding performance of the permanent cementation system you selected. KATANA™ Cleaner is our answer to this problem! Applied after conventional temporary cement removal, it provides optimal conditions for permanent cementation.

All relevant details are revealed in this scientific report.

Universal applicability of dental materials – this is a feature highly valued by the products’ users. It allows them to slim down the range of materials needed, which leads to reduced stock inventory and facilitates the establishment of universal workflows. With fewer variables and inconsistencies, all members of the practice team will know exactly what to do and how to do it, which mean less errors and consistent outcomes.

As one of the leading developers and providers of bonding agents, cements and composite filling as well as indirect restorative materials, Kuraray Noritake Dental strongly supports the universality trend in dentistry. Popular examples of universal products for direct restoration procedures are CLEARFIL™ Universal Bond Quick, a one-step dental bonding agent that works with or without a separate etching step, and the filling material CLEARFIL MAJESTY™ ES Flow.

Indirect restorative workflows are streamlined e.g. with PANAVIA™ SA Cement Universal, a self-adhesive resin cement indicated for all kinds of restorative materials, which is always used according to the same universal protocol.

Prior to the use of this product, the dental practitioner should consider cleaning the tooth and the restoration with KATANA™ Cleaner indicated for extra- and intra-oral use and providing optimal conditions for a strong and durable bond.

Both products recently received very positive ratings from the evaluators of Clinician’s Report. Click here to see the evaluations!

Universal applicability of dental materials – this is a feature highly valued by the products’ users. It allows them to slim down the range of materials needed, which leads to reduced stock inventory and facilitates the establishment of universal workflows. With fewer variables and inconsistencies, all members of the practice team will know exactly what to do and how to do it, which mean less errors and consistent outcomes.

As one of the leading developers and providers of bonding agents, cements and composite filling as well as indirect restorative materials, Kuraray Noritake Dental strongly supports the universality trend in dentistry. Popular examples of universal products for direct restoration procedures are CLEARFIL™ Universal Bond Quick, a one-step dental bonding agent that works with or without a separate etching step, and the filling material CLEARFIL MAJESTY™ ES Flow.

Indirect restorative workflows are streamlined e.g. with PANAVIA™ SA Cement Universal, a self-adhesive resin cement indicated for all kinds of restorative materials, which is always used according to the same universal protocol.

Prior to the use of this product, the dental practitioner should consider cleaning the tooth and the restoration with KATANA™ Cleaner indicated for extra- and intra-oral use and providing optimal conditions for a strong and durable bond.

Both products recently received very positive ratings from the evaluators of Clinician’s Report. Click here to see the evaluations!

By Marco Stoppaccioli

In today´s society, due to higher life expectancy, greater and more responsible attention to one´s body, we have developed a culture more sensitive to personal well-being. Consequently, more patients with total removable prostheses request stabilization of their prostheses through implant treatment which offers the most effective and valid response to this need.

The demand for implant treatments has increased significantly during the last decade, specifically from patients with long-term full prostheses resulting in considerable bone resorption¹, but are hesitant to undergo complex bone regeneration interventions (Photo 1).

These rehabilitations require great commitment and professional skills. In addition to restoring a complex series of aesthetic-functional parameters that have been lost. Innovative products were developed, not only the restoration of the dental, but also, the orthopedic aspects of the procedure.

Photo 1: Upper and lower Jaw situation models.

Initially, the dental-skeletal rehabilitations involved the exclusive use of metal posts combined with acrylic materials.

In recent decades, we have witnessed an evolution in the surgical techniques and materials used, among these, zirconia² has a significant and highly innovative role. The main reason for its success is due to the possibility of being able to use it anatomically through a simple and effective protocol thanks to CAD CAM technology.

Zirconia, created to be covered with ceramic coatings, has undergone a profound evolution: from an exclusively structural material with high strength but low aesthetic appeal, it has become anatomical, constituting an alternative to layered restorations. Thanks to research and innovation, optimizing chemical and physical parameters³ in the dental industry, we now have a wide range of products, including multi-layer zirconia.

In more analytical terms, it offers a very valid response to the translucency, which is inversely proportional to the flexural strength. On the market this material class oscillates between 550Mpa and 1200Mpa of flexural strength. This characteristic identifies its indication range, specifically depending on the yttrium oxide content, which acts as a stabilizer of zirconia.

For dental-skeletal rehabilitations, the protocol involves the use of multi-layer monolithic zirconia with marked characteristics of flexural strength but lower translucency which determines a limit in the aesthetic sense. On the other hand, the use of multi-layered zirconia with high translucency cannot be considered suitable, due to its lack of flexural strength, despite fully meeting the requirement for naturalness.

To date it can be said that there is no zirconia that offers high mechanical properties combined with high translucency, two fundamental aspects for successful restorations.

Considering these factors, the idea was born to generate an innovative and experimental protocol capable of supporting, on the one hand, the ability of CAD/CAM systems to copy exactly a project or even better, a functionalized provisional implant, and on the other, to associate the use of two zirconia with different characteristics: one extremely tough, white colored zirconia with 1125 MPa (KATANA™ HT Kuraray Noritake) and the other super translucent multi-layered zirconia with 750 MPa (KATANA™ STML Kuraray Noritake).

OPERATIONAL PROTOCOL

In dental-skeletal rehabilitations, success depends on a precise diagnosis by the clinician, aimed at the functional and aesthetic restoration of the case. It is a fundamental task of the dental technician to translate this information through the creation of a wax-up, both analog and digital.

Photo 2: Digital wax-up.

Photo 3: Analog wax-up.

Thanks to digitization, with a 3D printer, it is possible to realize the wax-up quickly and economically in a prototype, capable of allowing the clinician to perform an initial test in the oral cavity.

Photo 4: From design to 3D prototype.

Once the adequacy of the prototype under study has been certified, the next phase involves the construction of the provisional implant which, placed in the oral cavity for a specified time, provides the fundamental information from an occlusal point of view, both in static and dynamic conditions.

The first strength of this protocol is to capture all information about the provisional implant and transfer them to the final work through digital systems. In other words, the provisional implant itself becomes the design of the final product.

Photo 5: Temporary result of analog project.

Photo 6: Acquisition of temporary arches refitted on the models.

FINAL PROCEDURE: OPERATING PHASES

Once the scans of the temporary implant have been acquired in the digital platform, the structural frame obtained by reduction of the temporary implant file is generated. The framework will be made by using KATANA™ HT white colored zirconia (Kuraray Noritake Dental Inc.) with a flexural strength of 1125 MPa. This choice is attributable to an adequate toughness of the material and an effective aesthetic chromatic response on the pink ceramic coating.

Photo 7: Structural framework.

Photo 8: White zirconia framework, 1125 MPa (KATANA HT).

Once the structural file is generated, it is called up within the modeling software to create the anatomical components that will be divided into quadrants.

Photo 9: File divided into three seqments.

The selected material is multi-layered KATANA™ Zirconia STML by Kuraray Noritake Dental Inc. with a flexural strength of 750 MPa and high translucency. KATANA™ Zirconia STML shows an optimized balance between mechanical and optical characteristics.

The author's choice to divide the anatomical components into three segments has a dual purpose: the first is to have a better quality of the milling and the second is to reduce the material waste of the zirconia disc as much as possible.

Photo 10: The three segments after sintering.

Once the frameworks are obtained, before they are merged with each other, the anatomical parts are finished and polished; only the areas excluded from the functional part will be sandblasted. Special attention must be paid to the surface texturing of the anterior sectors⁵, with cutters, discs and rubbers dedicated for this purpose. The surfaces that remain shiny offer a lower abrasion coefficient than the natural tooth⁶; in fact, the abrasiveness depends on the surface smoothing. Polished zirconia has lower abrasion coefficients than lithium disilicate and layered ceramics⁷.

The adhesion between the anatomical and structural zirconia components is achieved by fusion with Noritake Cerabien ZR Low Fusion ceramic.

Photo 11: Anatomical components joined to the structural framework.

Once the adhesion between the zirconia components has been obtained, the first analog phase involves the creation of the gum parts, with dedicated pink gingival masses at a high temperature of 940 C° (CZR™ Tissue Kuraray Noritake Dental Inc.). The author selects three gingival masses with which the keratinized and vascularised parts are reproduced8, peculiar to the natural gingival tissue.

Photo 12: Used CZR™ Tissue porcelain.

Photo 13: Application of CZR™ Tissue porcelain.

Once the pink gingival parts are finalized, the coloring of the anatomical components will follow with the use of dedicated low temperature stains (CZR™ FC Paste Stain, Kuraray Noritake Dental Inc.) which, together with the high translucency of the anatomical zirconia, guarantees a high aesthetic result.

With gray, blue and black shades, it is possible to give a high degree of translucency to the incisal edges. With warm shades, like orange and yellow, the transitions of the anatomical crowns are emphasized, while with a few spots of strong color it is possible to give character and uniqueness to the teeth.

Photo 14: Used shades of CZR™ FC Paste Stain.

The low baking temperature of CZR™ FC Paste Stain guarantees the non-alteration of the gingival component. The final step involves glazing the sandblasted parts.

Photo 15: Final situation.

Photo 16: Occlusal view.

CONCLUSION

The strength of dento-skeletal rehabilitations made of monolithic zirconia, which is a stable, reliable and highly biocompatible material is, through the possibility of using CAD/CAM technology to make an exact copy of a case or, even better, a functionalized temporary implant.

Photo 17: Matching with wax-up.

The 1125 MPa zirconia is ideal for this type of prosthesis, however, does not offer an aesthetic quality. Therefore, the combination of two zirconia materials, one extremely strong and the other highly aesthetic, fully satisfies this requirement.

Photo 18, 19: Intra-oral situation.

BIBLIOGRAPHY:

1) Matteo Chiapasco, Eugenio Romeo La riabilitazione implantoprotesica nei casi compless, UTET S.p.A. 2003 Unione Tipografico-Editrice Torinese.

2) Piconi C. ,Rimondini L. ,Cerroni L. , La zirconia in odontoiatria, Masson, 2008.

3) Stawarczyk B., Ozcan M., Hallmann L., Ender A., Mehl A., Hammerle CH., Effect of zirconia sintering temperature on flexural strengh, grain size and contrast ratio. Clin oral investig, 2013.

5) Shigeo Kataoka, Yoshimi Nishimura , Morfologia naturale dei denti, Edizione internazionale Milano 2003
La riabilitazione implantoprotesica nei casi compless.

6) Oh W., Delong R., Anusavice K., Factors affecting enamel and ceramic wear: A literature review. J Prosthet Dent 2002.

7) Preis V., Bher M., Kolbeck C., Hahnel S., Handel G., Rosentritt M., Wear performance of substructure ceramics and veneering porcelains, Dent Mater, 2011.

8) Rutten L. & P., L’estetica su impianti, editrice MEA, 1999.

Thanks: Dr. Fortunato Alfonsi, Odt. Raoul Pietropaolo.

By Marco Stoppaccioli

In today´s society, due to higher life expectancy, greater and more responsible attention to one´s body, we have developed a culture more sensitive to personal well-being. Consequently, more patients with total removable prostheses request stabilization of their prostheses through implant treatment which offers the most effective and valid response to this need.

The demand for implant treatments has increased significantly during the last decade, specifically from patients with long-term full prostheses resulting in considerable bone resorption¹, but are hesitant to undergo complex bone regeneration interventions (Photo 1).

These rehabilitations require great commitment and professional skills. In addition to restoring a complex series of aesthetic-functional parameters that have been lost. Innovative products were developed, not only the restoration of the dental, but also, the orthopedic aspects of the procedure.

Photo 1: Upper and lower Jaw situation models.

Initially, the dental-skeletal rehabilitations involved the exclusive use of metal posts combined with acrylic materials.

In recent decades, we have witnessed an evolution in the surgical techniques and materials used, among these, zirconia² has a significant and highly innovative role. The main reason for its success is due to the possibility of being able to use it anatomically through a simple and effective protocol thanks to CAD CAM technology.

Zirconia, created to be covered with ceramic coatings, has undergone a profound evolution: from an exclusively structural material with high strength but low aesthetic appeal, it has become anatomical, constituting an alternative to layered restorations. Thanks to research and innovation, optimizing chemical and physical parameters³ in the dental industry, we now have a wide range of products, including multi-layer zirconia.

In more analytical terms, it offers a very valid response to the translucency, which is inversely proportional to the flexural strength. On the market this material class oscillates between 550Mpa and 1200Mpa of flexural strength. This characteristic identifies its indication range, specifically depending on the yttrium oxide content, which acts as a stabilizer of zirconia.

For dental-skeletal rehabilitations, the protocol involves the use of multi-layer monolithic zirconia with marked characteristics of flexural strength but lower translucency which determines a limit in the aesthetic sense. On the other hand, the use of multi-layered zirconia with high translucency cannot be considered suitable, due to its lack of flexural strength, despite fully meeting the requirement for naturalness.

To date it can be said that there is no zirconia that offers high mechanical properties combined with high translucency, two fundamental aspects for successful restorations.

Considering these factors, the idea was born to generate an innovative and experimental protocol capable of supporting, on the one hand, the ability of CAD/CAM systems to copy exactly a project or even better, a functionalized provisional implant, and on the other, to associate the use of two zirconia with different characteristics: one extremely tough, white colored zirconia with 1125 MPa (KATANA™ HT Kuraray Noritake) and the other super translucent multi-layered zirconia with 750 MPa (KATANA™ STML Kuraray Noritake).

OPERATIONAL PROTOCOL

In dental-skeletal rehabilitations, success depends on a precise diagnosis by the clinician, aimed at the functional and aesthetic restoration of the case. It is a fundamental task of the dental technician to translate this information through the creation of a wax-up, both analog and digital.

Photo 2: Digital wax-up.

Photo 3: Analog wax-up.

Thanks to digitization, with a 3D printer, it is possible to realize the wax-up quickly and economically in a prototype, capable of allowing the clinician to perform an initial test in the oral cavity.

Photo 4: From design to 3D prototype.

Once the adequacy of the prototype under study has been certified, the next phase involves the construction of the provisional implant which, placed in the oral cavity for a specified time, provides the fundamental information from an occlusal point of view, both in static and dynamic conditions.

The first strength of this protocol is to capture all information about the provisional implant and transfer them to the final work through digital systems. In other words, the provisional implant itself becomes the design of the final product.

Photo 5: Temporary result of analog project.

Photo 6: Acquisition of temporary arches refitted on the models.

FINAL PROCEDURE: OPERATING PHASES

Once the scans of the temporary implant have been acquired in the digital platform, the structural frame obtained by reduction of the temporary implant file is generated. The framework will be made by using KATANA™ HT white colored zirconia (Kuraray Noritake Dental Inc.) with a flexural strength of 1125 MPa. This choice is attributable to an adequate toughness of the material and an effective aesthetic chromatic response on the pink ceramic coating.

Photo 7: Structural framework.

Photo 8: White zirconia framework, 1125 MPa (KATANA HT).

Once the structural file is generated, it is called up within the modeling software to create the anatomical components that will be divided into quadrants.

Photo 9: File divided into three seqments.

The selected material is multi-layered KATANA™ Zirconia STML by Kuraray Noritake Dental Inc. with a flexural strength of 750 MPa and high translucency. KATANA™ Zirconia STML shows an optimized balance between mechanical and optical characteristics.

The author's choice to divide the anatomical components into three segments has a dual purpose: the first is to have a better quality of the milling and the second is to reduce the material waste of the zirconia disc as much as possible.

Photo 10: The three segments after sintering.

Once the frameworks are obtained, before they are merged with each other, the anatomical parts are finished and polished; only the areas excluded from the functional part will be sandblasted. Special attention must be paid to the surface texturing of the anterior sectors⁵, with cutters, discs and rubbers dedicated for this purpose. The surfaces that remain shiny offer a lower abrasion coefficient than the natural tooth⁶; in fact, the abrasiveness depends on the surface smoothing. Polished zirconia has lower abrasion coefficients than lithium disilicate and layered ceramics⁷.

The adhesion between the anatomical and structural zirconia components is achieved by fusion with Noritake Cerabien ZR Low Fusion ceramic.

Photo 11: Anatomical components joined to the structural framework.

Once the adhesion between the zirconia components has been obtained, the first analog phase involves the creation of the gum parts, with dedicated pink gingival masses at a high temperature of 940 C° (CZR™ Tissue Kuraray Noritake Dental Inc.). The author selects three gingival masses with which the keratinized and vascularised parts are reproduced8, peculiar to the natural gingival tissue.

Photo 12: Used CZR™ Tissue porcelain.

Photo 13: Application of CZR™ Tissue porcelain.

Once the pink gingival parts are finalized, the coloring of the anatomical components will follow with the use of dedicated low temperature stains (CZR™ FC Paste Stain, Kuraray Noritake Dental Inc.) which, together with the high translucency of the anatomical zirconia, guarantees a high aesthetic result.

With gray, blue and black shades, it is possible to give a high degree of translucency to the incisal edges. With warm shades, like orange and yellow, the transitions of the anatomical crowns are emphasized, while with a few spots of strong color it is possible to give character and uniqueness to the teeth.

Photo 14: Used shades of CZR™ FC Paste Stain.

The low baking temperature of CZR™ FC Paste Stain guarantees the non-alteration of the gingival component. The final step involves glazing the sandblasted parts.

Photo 15: Final situation.

Photo 16: Occlusal view.

CONCLUSION

The strength of dento-skeletal rehabilitations made of monolithic zirconia, which is a stable, reliable and highly biocompatible material is, through the possibility of using CAD/CAM technology to make an exact copy of a case or, even better, a functionalized temporary implant.

Photo 17: Matching with wax-up.

The 1125 MPa zirconia is ideal for this type of prosthesis, however, does not offer an aesthetic quality. Therefore, the combination of two zirconia materials, one extremely strong and the other highly aesthetic, fully satisfies this requirement.

Photo 18, 19: Intra-oral situation.

BIBLIOGRAPHY:

1) Matteo Chiapasco, Eugenio Romeo La riabilitazione implantoprotesica nei casi compless, UTET S.p.A. 2003 Unione Tipografico-Editrice Torinese.

2) Piconi C. ,Rimondini L. ,Cerroni L. , La zirconia in odontoiatria, Masson, 2008.

3) Stawarczyk B., Ozcan M., Hallmann L., Ender A., Mehl A., Hammerle CH., Effect of zirconia sintering temperature on flexural strengh, grain size and contrast ratio. Clin oral investig, 2013.

5) Shigeo Kataoka, Yoshimi Nishimura , Morfologia naturale dei denti, Edizione internazionale Milano 2003
La riabilitazione implantoprotesica nei casi compless.

6) Oh W., Delong R., Anusavice K., Factors affecting enamel and ceramic wear: A literature review. J Prosthet Dent 2002.

7) Preis V., Bher M., Kolbeck C., Hahnel S., Handel G., Rosentritt M., Wear performance of substructure ceramics and veneering porcelains, Dent Mater, 2011.

8) Rutten L. & P., L’estetica su impianti, editrice MEA, 1999.

Thanks: Dr. Fortunato Alfonsi, Odt. Raoul Pietropaolo.

Users of dental zirconia are really spoilt for choice these days. Countless manufacturers offer zirconia materials that differ in their mechanical and optical properties and indication range. What is not apparent at first sight is that the available products also differ with respect to the quality of the CAD/CAM blanks offered. Blank quality is highly dependent on the quality of the raw materials and is affected by different aspects during raw material processing, pressing and pre-sintering. This has a huge impact on the surface quality, edge stability, fit and processing requirements of milled restorations.

Raw material production

Pre-shaded dental zirconia typically consists of metal oxides, including zirconium oxide, yttrium oxide and aluminium oxide, as well as additives like binders and colour pigments or ions. Most manufacturers of dental zirconia obtain pre-fabricated powder from an external industry partner, the most popular option being Tosoh Corporation. In contrast, Kuraray Noritake Dental relies on an end-to-end in-house process. This includes the production and addition of the components forming the company’s innovative multilayered technology, which makes it possible to match the shades in the polychromatic blanks precisely to the colours of the VITA classical A1-D4 shade guide.

At Kuraray Noritake Dental, the powder is produced in-house.

Since more powder production steps are carried out in-house, this gives the company full control of the quality of the raw materials, their grain size and the purity of the formulation. It also allows for a precise alignment of the mechanical and optical product properties. Properties of zirconia restorations that are affected by the powder quality and composition include translucency and shade appearance, flexural strength, ageing behaviour and sintering performance.

Blank pressing

Zirconia discs and blocks used for CAD/CAM processing are usually produced by uniaxial and isostatic pressing. In the uniaxial compaction process, pressure is applied to the powder from one direction (uniaxial) or two directions (biaxial), whereas the isostatic compaction process involves virtually equal pressure applied from all sides. Hence, isostatic pressing typically results in a more uniform density distribution throughout the blank and a higher material homogeneity. These factors are prerequisites for a predictable processing and sintering behaviour and affect the fit of the final restoration. For optimal mechanical and optical properties of the zirconia material, it is essential to avoid large porosities, air pockets and impurities caused by airborne particles that are trapped during pressing.

At Kuraray Noritake Dental, a unique and extremely meticulous pressing process achieves a uniform pressure distribution and low risk of contamination by airborne particles. This specific procedure reduces gravitation forces and contributes to having as high as possible density of zirconia material. All the high-level preparation processes from raw material production to pressing are responsible for the high edge stability and surface quality of restorations milled from KATANA™ Zirconia.”

Pre-sintering

The pre-sintering procedure is necessary in that it gives the pressed blanks the required stability to be machinable with milling tools. The selected temperature profile and duration of the pre-sintering cycle determine the material’s strength and processing properties and have an impact on the final sintering process.

The unique pre-sintering procedure carried out in the production facilities of Kuraray Noritake Dental results in blanks that are stable in their pre-sintered state. Although more stable, pre-sintered KATANA™ Zirconia is machinable with common diamond-coated milling tools without any increased risk of breakage or higher tool wear.

A KATANA™ Zirconia blank ready for milling.

Fast sintering for the laboratory

The unique procedure has a positive impact on the surface smoothness after milling and can significantly shorten sintering times. In fact, the speed sintering program offered for all variants of KATANA™ Zirconia is the fastest one on the market. In the dental laboratory, the sintering times may be reduced to 90 minutes^*for single-tooth restorations and bridges of up to three units.

^*The material is removed from the furnace at 800°C.

Overview of the recommended sintering protocols.

Fast sintering for chairside

Using the KATANA™ Zirconia block with Dentsply Sirona’s CEREC system, it is possible to sinter single crowns up to three-unit bridges in 18-30 minutes without compromising the mechanical or optical properties.

The KATANA™ Zirconia block displays superior optical properties after 18 minutes of sintering compared with representatives of major competitors’ raw material after 30-minute and 60-minute sintering programs designed by Kuraray Noritake Dental based on the manufacturer's recommendations.

Unique KATANA™ Zirconia properties

Together, these efforts taken by Kuraray Noritake Dental to produce dental zirconia of exceptionally high quality make all the difference. The KATANA™ Zirconia series - KATANA™ Zirconia Ultra Translucent Multi Layered (UTML), Super Translucent Multi Layered (STML), High Translucent Multi Layered (HTML) and KATANA™ Zirconia High Translucent Mono Layered (HT) - have a homogeneous, high-density structure with low porosity and a high level of purity. This optimises the performance of the blanks during machining.

Surface roughness

SEM image, magnification 33X, of competitor material surface roughness. Image courtesy of Dr Kunkela, Kunkela Research Academy.

SEM image, magnification 33X, of KATANA Zirconia surface roughness. Image courtesy of Dr Kunkela, Kunkela Research Academy.

SEM images of non-polished KATANA™ Zirconia and a competitor’s material at 33x magnification. The four images of each material show the surface structure at different areas of a molar crown. In all areas, the surface of the restoration made of the competitor’s material is rougher and shows more porosity than the surface of the KATANA™ Zirconia crown directly after milling, according to Dr Josef Kunkela’s research results. One of the contributing factors to this result is the more densely pressed blanks with smaller grain sizes of KATANA™ Zirconia.

An optimised processing behaviour leads to regular restoration margins, smooth surfaces and a precise fit of the restorations. The latter is due to the fact that the milling behaviour and volumetric shrinkage during final sintering are highly predictable, so that a user designing a 20 µm cement gap will get what he or she desires. Owing to the great control over optical properties and precise match to the VITA classical A1-D4 shades, KATANA™ Zirconia is considered to be one of the most aesthetic dental zirconia options available on the market.

Excellent marginal fit

SEM images revealing the fit of restorations made of two different materials (lithium disilicate and KATANA™ Zirconia Block STML) on a tooth abutment. The KATANA™ Zirconia restoration shows a more regular margin and more precise fit (with a cement gap of 19-21 µm) than the lithium disilicate crown (cement gap 26-45 µm). Images courtesy of Dr Kunkela, Kunkela Research Academy.

Extremely regular margins of a KATANA™ Zirconia crown after milling, which is also a result of the favourable material structure.

In order to ensure all the desired material properties, including aesthetics and strength, one thing is essential: the machining carried out in the dental laboratory - milling and sintering - needs to adhere to the recommended protocols. This means that the milling machine and furnace should be cleaned and calibrated on a regular basis, which provides the conditions for optimised zirconia processing from the powder to the final, true-to-life dental restoration.

Users of dental zirconia are really spoilt for choice these days. Countless manufacturers offer zirconia materials that differ in their mechanical and optical properties and indication range. What is not apparent at first sight is that the available products also differ with respect to the quality of the CAD/CAM blanks offered. Blank quality is highly dependent on the quality of the raw materials and is affected by different aspects during raw material processing, pressing and pre-sintering. This has a huge impact on the surface quality, edge stability, fit and processing requirements of milled restorations.

Raw material production

Pre-shaded dental zirconia typically consists of metal oxides, including zirconium oxide, yttrium oxide and aluminium oxide, as well as additives like binders and colour pigments or ions. Most manufacturers of dental zirconia obtain pre-fabricated powder from an external industry partner, the most popular option being Tosoh Corporation. In contrast, Kuraray Noritake Dental relies on an end-to-end in-house process. This includes the production and addition of the components forming the company’s innovative multilayered technology, which makes it possible to match the shades in the polychromatic blanks precisely to the colours of the VITA classical A1-D4 shade guide.

At Kuraray Noritake Dental, the powder is produced in-house.

Since more powder production steps are carried out in-house, this gives the company full control of the quality of the raw materials, their grain size and the purity of the formulation. It also allows for a precise alignment of the mechanical and optical product properties. Properties of zirconia restorations that are affected by the powder quality and composition include translucency and shade appearance, flexural strength, ageing behaviour and sintering performance.

Blank pressing

Zirconia discs and blocks used for CAD/CAM processing are usually produced by uniaxial and isostatic pressing. In the uniaxial compaction process, pressure is applied to the powder from one direction (uniaxial) or two directions (biaxial), whereas the isostatic compaction process involves virtually equal pressure applied from all sides. Hence, isostatic pressing typically results in a more uniform density distribution throughout the blank and a higher material homogeneity. These factors are prerequisites for a predictable processing and sintering behaviour and affect the fit of the final restoration. For optimal mechanical and optical properties of the zirconia material, it is essential to avoid large porosities, air pockets and impurities caused by airborne particles that are trapped during pressing.

At Kuraray Noritake Dental, a unique and extremely meticulous pressing process achieves a uniform pressure distribution and low risk of contamination by airborne particles. This specific procedure reduces gravitation forces and contributes to having as high as possible density of zirconia material. All the high-level preparation processes from raw material production to pressing are responsible for the high edge stability and surface quality of restorations milled from KATANA™ Zirconia.”

Pre-sintering

The pre-sintering procedure is necessary in that it gives the pressed blanks the required stability to be machinable with milling tools. The selected temperature profile and duration of the pre-sintering cycle determine the material’s strength and processing properties and have an impact on the final sintering process.

The unique pre-sintering procedure carried out in the production facilities of Kuraray Noritake Dental results in blanks that are stable in their pre-sintered state. Although more stable, pre-sintered KATANA™ Zirconia is machinable with common diamond-coated milling tools without any increased risk of breakage or higher tool wear.

A KATANA™ Zirconia blank ready for milling.

Fast sintering for the laboratory

The unique procedure has a positive impact on the surface smoothness after milling and can significantly shorten sintering times. In fact, the speed sintering program offered for all variants of KATANA™ Zirconia is the fastest one on the market. In the dental laboratory, the sintering times may be reduced to 90 minutes^*for single-tooth restorations and bridges of up to three units.

^*The material is removed from the furnace at 800°C.

Overview of the recommended sintering protocols.

Fast sintering for chairside

Using the KATANA™ Zirconia block with Dentsply Sirona’s CEREC system, it is possible to sinter single crowns up to three-unit bridges in 18-30 minutes without compromising the mechanical or optical properties.

The KATANA™ Zirconia block displays superior optical properties after 18 minutes of sintering compared with representatives of major competitors’ raw material after 30-minute and 60-minute sintering programs designed by Kuraray Noritake Dental based on the manufacturer's recommendations.

Unique KATANA™ Zirconia properties

Together, these efforts taken by Kuraray Noritake Dental to produce dental zirconia of exceptionally high quality make all the difference. The KATANA™ Zirconia series - KATANA™ Zirconia Ultra Translucent Multi Layered (UTML), Super Translucent Multi Layered (STML), High Translucent Multi Layered (HTML) and KATANA™ Zirconia High Translucent Mono Layered (HT) - have a homogeneous, high-density structure with low porosity and a high level of purity. This optimises the performance of the blanks during machining.

Surface roughness

SEM image, magnification 33X, of competitor material surface roughness. Image courtesy of Dr Kunkela, Kunkela Research Academy.

SEM image, magnification 33X, of KATANA Zirconia surface roughness. Image courtesy of Dr Kunkela, Kunkela Research Academy.

SEM images of non-polished KATANA™ Zirconia and a competitor’s material at 33x magnification. The four images of each material show the surface structure at different areas of a molar crown. In all areas, the surface of the restoration made of the competitor’s material is rougher and shows more porosity than the surface of the KATANA™ Zirconia crown directly after milling, according to Dr Josef Kunkela’s research results. One of the contributing factors to this result is the more densely pressed blanks with smaller grain sizes of KATANA™ Zirconia.

An optimised processing behaviour leads to regular restoration margins, smooth surfaces and a precise fit of the restorations. The latter is due to the fact that the milling behaviour and volumetric shrinkage during final sintering are highly predictable, so that a user designing a 20 µm cement gap will get what he or she desires. Owing to the great control over optical properties and precise match to the VITA classical A1-D4 shades, KATANA™ Zirconia is considered to be one of the most aesthetic dental zirconia options available on the market.

Excellent marginal fit

SEM images revealing the fit of restorations made of two different materials (lithium disilicate and KATANA™ Zirconia Block STML) on a tooth abutment. The KATANA™ Zirconia restoration shows a more regular margin and more precise fit (with a cement gap of 19-21 µm) than the lithium disilicate crown (cement gap 26-45 µm). Images courtesy of Dr Kunkela, Kunkela Research Academy.

Extremely regular margins of a KATANA™ Zirconia crown after milling, which is also a result of the favourable material structure.

In order to ensure all the desired material properties, including aesthetics and strength, one thing is essential: the machining carried out in the dental laboratory - milling and sintering - needs to adhere to the recommended protocols. This means that the milling machine and furnace should be cleaned and calibrated on a regular basis, which provides the conditions for optimised zirconia processing from the powder to the final, true-to-life dental restoration.

KATANA™ Zirconia Block has hardly any common features with the zirconium oxide that captured dental laboratories two decades ago and was used as a framework material. In many cases, the innovative zirconia serves as a functionally and aesthetically sensible alternative to high-strength glass ceramics. Its flexural strength is higher than that of lithium disilicate, its translucency on a level with the LT variant of the ceramic and its surface – if smoothly polished – antagonist-friendly causing low wear. Apart from its natural translucency, the multi-layered structure of KATANA™ Zirconia Block with four gradient shades precisely imitating natural colour gradients found in anterior and posterior teeth leads to highly aesthetic outcomes.

In order to exploit the full potential of the cubic zirconia KATANA™ Zirconia Block, users of the CEREC system need to adopt slightly different automatic and manual processing strategies than for glass ceramic processing. The following answers to frequently asked questions provide information on the most important differences and tips and tricks that help achieve the best possible results.

COMPUTER-AIDED DESIGN

What is the best position of the restoration in the block to leverage all benefits related to the multi-layered structure?

Ideally, a restoration is positioned in the middle of the block. In addition, the selected block should be one shade darker than the determined shade. This will lead to a natural shade appearance of the resulting restoration. If the restoration is placed at the upper margin of the block, parts of the body shade – and with it chroma – are lost, which makes the restoration appear too light.

How are chipping effects in the area of the milling sprues (most often occurring in bridges) effectively prevented?

Marginal chipping in these areas might appear due to an uneven force distribution during milling. The problem is easily overcome by designing two milling sprues per crown or bridge unit.

COMPUTER-MANUFACTURING

Is wet or dry milling the best option to process KATANA™ Zirconia Block?

The best results are obtained with dry milling. This procedure also leads to time-savings, as there is no need for drying after processing.

When opting for wet milling: Are there any particularities that need to be respected for KATANA™ Zirconia Block?

Those users opting for wet milling and utilizing the same machine for the processing of zirconia and glass ceramics should implement a system utilizing three water tanks. One tank is filled with wash water, the tank used for processing of glass-based ceramics is filled with water and additives (such as Dentatec, Dentsply Sirona) and the one used for processing of zirconia contains purified/distilled water without any additives.

Moreover, a prerequisite for a high quality of the manufactured restorations is that the machine is cleaned thoroughly every time before a different material is processed.

The following components need to be cleaned:

• the milling tools
• the interior of the machine
• the water tank(s)
• all filters

Typically, zirconia reacts to milling additives (Dentatec) in the water with a reduced translucency, so that their use cannot be recommended. Residues of glass ceramic particles found on milling tools, in the water or in the interior of the machine might also have a negative impact on the aesthetic appearance of KATANA™ restorations (typical effect: white spots on the surface).

When is it necessary to replace milling tools used for the processing of KATANA™ Zirconia Block?

It is recommended to replace the tool sets every 10 to 15 units. At this time, the degree of tool wear amounts to approximately 50 percent. Those who continue using the tools accept an increased risk of weakening the oxide ceramic’s microstructure: worn milling tools are likely to produce micro cracks and micro chipping. When these defects occur between the different units of a bridge, they increase the risk for chipping and fractures.

MANUAL POST-PROCESSING

Are there any specific measures to be taken when removing the block from the machine?

When machining is completed, the restoration should be touched only by individuals wearing gloves. Even after thorough washing, bare hands will release fats, which may lead to smear formation and a reduced translucency of the oxide ceramic material.

How are the restorations cleaned after sprue removal?

Powder residues should be removed after processing with a gentle stream of air. Alternatively, a fine (and obviously clean) brush may be used for the removal of the zirconia dust. Powder residues remaining on the restoration surface might lead to the occurrence or white spots or to smear formation. Steam-cleaning of the restoration should be avoided as this measure dramatically increases the pores in the material and alters the material properties.

When is the right time to add fissures and texture to the surface of the restoration and how is this task accomplished?

Ideally, all those details that cannot be incorporated by a milling machine (surface texture, fissures etc.) are added in the restoration’s pre-sintered state, i.e. between milling and final sintering. Diamond milling tools for oxide ceramics should be used at a low speed (7,000 to 10,000 rpm) for this purpose.

TANK MANAGEMENT: CLEANING PROCEDURE AFTER USING GLASS CERAMICS

Be sure the glass ceramic cooling-water tank is installed. Press the Pump button on the touch panel to wash away any glass ceramic powder that is inside the milling chamber. Then, thoroughly flush milling debris from the milling chamber filter and milling powder from beneath the milling chamber filter.

FINAL SINTERING

What are the particularities to be respected during final sintering of restorations made of KATANA™ Zirconia Block material?

Zirconia restorations are subject to volumetric shrinkage (approximately 20 percent) during sintering. Therefore, it is essential to not place the restoration on a rigid carrier during sintering. If the volume of the restoration is reduced while the volume of the carrier is not, the risk of fracture is high. Ideally, the restoration is placed on its largest side.

What measures should be taken to avoid discoloration of a restoration during sintering?

Discoloration (usually leading to a green-yellowish appearance) might be the result of contamination of the sintering furnace with metal oxides. These metal oxides originate from other materials processed in the furnace. They are released during sintering and absorbed by the restoration. Running a decontamination programme on a regular basis is an effective measure that helps prevent discoloration. For this purpose, white zirconium oxide (either collected from odds and ends of non-shaded blanks or purchased) is placed in the furnace chamber and a sintering programme is started. As the furnace CEREC® SpeedFire does not offer a specific decontamination programme, there is no way around working a fiddle: the user simply creates two separate jobs for the sintering of two single crowns, but sinters them together. The second job is used for the decontamination cycle. During this procedure, the white zirconium oxide absorbs the metal oxides, which has a cleaning effect on the furnace.

CHARACTERISATION

Which techniques are best suited for an optical refinement of monolithic restorations made of KATANA™ Zirconia Block?

A material designed for this kind of refinement is CERABIEN™ ZR FC Paste Stain from Kuraray Noritake Dental. The paste-like shading solutions are filled with ceramic particles. Therefore, the optical effects achievable with these pastes are much more durable than those obtained with classical stains. As all pastes are fluorescent, it is possible to produce a natural long-term fluorescence effect without an additional work step. With just four shades of the liquid ceramic – A+, Grayish Blue, Value and Clear Glaze – it is possible to perfectly characterize 85 percent of all restorations made of KATANA™ Zirconia Block material. The firing temperature is 750 °C and the CTE values of CERABIEN™ ZR FC Paste Stain and KATANA™ Zirconia Block are precisely adjusted to each other. The product is also very well suited for glass ceramic characterization.

How is it possible to hold the restoration during characterization?

The easiest option is the use of putty material on a carrier. The crown is simply placed on the unset putty and then positioned on the carrier. The surface of the restoration should be cleaned with a gentle stream of air before applying the pastes. Thanks to the ceramic particles in CERABIEN™ ZR FC Paste Stain, the pastes stay put during processing and do not flow away.

POLISHING

How to ensure a low wear of the antagonist?

Zirconium oxide stands out due to its hardness, which makes careful polishing of the surface a prerequisite for clinical use. After characterization with CERABIEN™ ZR FC Paste Stain, polishing of all occlusal contact areas is mandatory as well. The polishing set Polierset KATANA™ Twist DIA even allows for intraoral use.

PLACEMENT

What kind of resin cement is recommended for the definitive placement of restorations made of KATANA™ Zirconia Block material?

The best possible results are obtained with PANAVIA™ V5. This adhesive resin cement system is responsible for the development of a particularly strong bond between the tooth structure and the restoration, which also has a strengthening effect on the restoration.