Testing the strength of thin feather-edge monolithic multilayered zirconia crowns: A pilot study with a novel acoustic test
Authors: SAAB Estelle , HADDAD Camille , ABBOUD Maher , DAOU Maha , EL ZOGHBI Amine 
Published: October 2024

Intoduction: Limited research has explored the mechanical characteristics of recently introduced multilayered monolithic zirconia (MZC) crowns with feather-edge margins design. Moreover, most of the conventional techniques for evaluating the mechanical behavior of brittle dental ceramics rely on destructive tests, making it impossible to precisely evaluate real strength values due to premature crack initiation detection failure.
Objectives: The main objective of the study was to assess the load capacity of translucent multilayered monolithic zirconia crowns with feather-edge margin thicknesses of 0.4 mm and 0.5 mm. Additionally, the research introduced a novel non-destructive acoustic emission testing (AET) technique in the laboratory to identify early cracks in dental ceramics.
Methods: Forty multilayered zirconia crowns produced using computer-aided design and computer-aided manufacturing (CAD/CAM) technology were evenly divided into two groups, each with distinct feather-edge margin thicknesses: 0.5 mm (group 1) and 0.4 mm (group 2). These crowns were securely cemented onto customized polymethyl methacrylate (PMMA) dies using a universal restorative glass ionomer. Subsequently, the crowns underwent a compressive axial loading test, controlled by an innovative AET crack detection system rooted in the principles of non-destructive laboratory testing. Fractographic analysis was conducted to determine the location of crack or eventual fracture.
Results: The proportion of MZCs with a crack was statistically higher than the proportion with a fracture in the whole sample (p<0.001). In addition, the results showed that the crowns in group 1 exhibited higher loading values than those in group 2. The mean loading capacity in group was 911.2 N ± 614.7 N. Two locations of crack and fracture were registered: occlusal and marginal. No statistical association was observed between the two groups for the location of cracks or fractures.
Conclusions: The feather-edge crowns with a 0.5 mm margin thickness had a higher loading capacity than those with a 0.4 mm. However, the latter supports loads that exceed occlusal force in the oral cavity suggesting that 0.4 mm feathered edge MZCs may be a valid and less invasive alternative to thicker margins. The novel load-to-fracture AET setup proved effective in detecting early crack initiation, suggesting it as a promising method for assessing the mechanical properties of brittle materials prior to failure, potentially impacting the field of dentistry. However more advanced research is needed to enhance the accuracy of the proposed technique.
Clinical implications: The examined MZC demonstrates the ability to withstand occlusal forces in a patient’s mouth, offering clinical practitioners the option of embracing minimally invasive dentistry through the use of 0.4 mm feather-edge MZC in their treatment options. Furthermore, the positive results from the innovative acoustic emission testing technique, facilitating early crack detection, indicate a promising future for studying the behavior of brittle materials in dental laboratory testing.