Fracture strength of four-unit Y-TZP FPD cores designed with varying connector diameter. An in-vitro study

Reported clinical success rates of all-ceramic fixed partial dentures (FPDs) made of high-strength oxide ceramics range between 82.5% and 100%. The main cause of all-ceramic FPD failure is fracture in the connector area. There is, however, no consensus on what connector dimensions are adequate. The aim of this in-vitro study was, therefore, to compare the fracture strength of four-unit Y-TZP FPD cores designed with different connector diameters. A total of 40 four-unit FPD cores supported by end abutments and having two pontics were manufactured in Procera Zirconia. Five groups of FPD cores with connector dimensions of 2.0, 2.5, 3.0, 3.5 and 4.0 mm were produced. All FPD cores underwent a firing programme according to the manufacturer's recommendations for the veneering porcelain, a cyclic preload, thermocycling and finally, load until fracture. Fracture strength was significantly higher for each increase in connector diameter except for the 2.0-mm and 2.5-mm diameters where all fractures occurred during preload. All FPD cores fractured in the connector area. Within the limitations of this in-vitro study, a minimum diameter of 4.0 mm is recommended for all-ceramic zirconia-based FPDs with long spans or replacing molars. Clinical studies are, however, needed to determine adequate connector dimensions.