Laboratory simulation of Y-TZP all-ceramic crown clinical failures.

Clinically, zirconia-supported all-ceramic restorations are failing by veneer-chipping without exposing the zirconia interface. We hypothesized that mouth motion step-stress-accelerated fatigue testing of standardized dental crowns would permit this previously unrecognized failure mode to be investigated. Using CAD software, we imported the average dimensions of a mandibular first molar crown and modeled tooth preparation. The CAD-based tooth preparation was rapid-prototyped as a die for fabrication of zirconia core porcelain-veneered crowns. Crowns were bonded to aged composite reproductions of the preparation and aged 14 days in water. Crowns were single-cycle-loaded to failure or mouth-motion step-stress- fatigue-tested. Finite element analysis indicated high stress levels below the load and at margins, in agreement with only single-cycle fracture origins. As hypothesized, the mouth motion sliding contact fatigue resulted in veneer chipping, reproducing clinical findings allowing for investigations into the underlying causes of such failures.