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New Speed-Sintered CaO-Zirconia for Strong, Tough, Translucent Restorations.

A Vettorel1,2, B V Meerbeek1, J Vleugels2

  • 1KU Leuven, Department of Oral Health Sciences, BIOMAT & UZ Leuven, Dentistry, Leuven, Belgium.

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Summary

Chairside speed-sintering of 4.5 mol% CaO-stabilized tetragonal zirconia polycrystal (4.5Ca-TZP) yields fully dense ceramics with excellent mechanical reliability and aging resistance. This advanced zirconia offers a tougher alternative for dental restorations compared to conventional yttria-stabilized zirconia.

Keywords:
CAD-CAMceramicsmaterials science(s)mechanical propertiesrestorative dentistryrestorative materials

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Area of Science:

  • Materials Science
  • Biomaterials
  • Dental Ceramics

Background:

  • Conventional yttria-stabilized zirconia (3Y-TZP) used in dental restorations has limitations due to a trade-off between mechanical strength and optical properties.
  • There is a growing demand for rapid, esthetic, and reliable ceramic dental materials manufactured chairside.

Purpose of the Study:

  • To investigate the feasibility of chairside speed-sintering for 4.5 mol% CaO-stabilized tetragonal zirconia polycrystal (4.5Ca-TZP).
  • To evaluate the microstructure, mechanical reliability, translucency, and aging resistance of speed-sintered 4.5Ca-TZP.

Main Methods:

  • Nano-sized 4.5Ca-TZP powders were compacted and speed-sintered within 60 minutes at temperatures ranging from 1,250 °C to 1,350 °C.
  • Evaluated properties included relative density, grain size, hardness, monoclinic content, fracture toughness, translucency, hydrothermal aging resistance, biaxial strength, and Weibull modulus.
  • A proof-of-concept CAD/CAM-milled crown was fabricated to assess chairside applicability.

Main Results:

  • Speed-sintering produced fully dense (≥99% relative density) 4.5Ca-TZP with a fine microstructure (<200 nm) and minimal monoclinic phase (≤2 vol%).
  • The material exhibited excellent mechanical reliability (characteristic strength ≥1.1 GPa, Weibull modulus ≥11) and resistance to hydrothermal aging.
  • Translucency peaked at 1,250 °C (≈22), and no radial cracks were observed after sintering above 1,300 °C.

Conclusions:

  • Chairside speed-sintering of 4.5Ca-TZP is feasible, resulting in a fully dense zirconia with superior mechanical reliability and aging resistance compared to conventional 3Y-TZP.
  • This material presents a promising, tougher alternative for esthetic dental restorations manufactured rapidly chairside.
  • Further research is needed on long-term durability, large-scale manufacturing, and dimensional accuracy for clinical application.