In-vitro fit of experimental full-arch restorations made from monolithic zirconia

Purpose: Fabrication inaccuracies can compromise the fit of large-span monolithic zirconia restorations. Sintering distortion is a particular problem. This study aimed to assess the fit of full-arch restorations made from monolithic zirconia for different abutment configurations. Methods: To quantify fit inaccuracies created during the fabrication of experimental large-span restorations, an in-vitro model with eight abutment teeth was equipped with strain gauges. Ten 14-unit restorations were made from monolithic zirconia and seated on the model in turn. For each of the ten restorations, measurements were taken for three different abutment configurations-polygonal, quadrangular, and unilaterally shortened. Strains exerted during seating were recorded in the anterior-posterior and buccal-palatal directions, and the resulting horizontal forces (rhF) were calculated along with the respective abutment deflection (ad). Data were analyzed using Kruskal-Wallis tests at a significance level of 0.05. Results: All restorations could be seated on the multi-abutment model. The restorations exhibited fabrication misfits, tending to be too wide. Mean rhF/ad were largest for the quadrangular configuration (16.8 +/- 2.9 N/0.065 mm) and smallest for the polygonal configuration (13.6 +/- 4.5 N/0.053 mm). The largest rhF/ad were measured on abutments of the unilaterally shortened configuration, with a maximum deflection of 0.126 mm. For two of three configurations, rhF/ad were significantly larger for the distal abutments than for the other abutments. Conclusion: Even if milling and sintering procedures are optimum, misfit-induced horizontal forces cannot be avoided. Because of the natural tooth mobility, however, the fit of full-arch restorations made from monolithic zirconia might be clinically acceptable.