Influence of core material and occlusal contact pattern on fatigue behavior of different monolithic ceramic crowns

Maria Gabriela Packaeser; Renan Vaz Machry; Elisa Donaria Aboucauch Grassi; Guilherme de Siqueira Ferreira Anzaloni Saavedra; Cornelis Johannes Kleverlaan; Luiz Felipe Valandro; João Paulo Mendes Tribst; Gabriel Kalil Rocha Pereira

doi:10.1016/j.jmbbm.2025.106891

Influence of core material and occlusal contact pattern on fatigue behavior of different monolithic ceramic crowns

Maria Gabriela Packaeser
, Renan Vaz Machry
, Elisa Donaria Aboucauch Grassi
, Guilherme de Siqueira Ferreira Anzaloni Saavedra
, Cornelis Johannes Kleverlaan
, Luiz Felipe Valandro
, João Paulo Mendes Tribst^*
, Gabriel Kalil Rocha Pereira

^*Corresponding author for this work

Research output: Contribution to Journal › Article › Academic › peer-review

Abstract

This study evaluated the effect of substrate core materials and occlusal contact patterns on the fatigue mechanical behavior and stress distribution of single-unit ceramic crowns. One hundred and twenty monolithic crowns were fabricated from zirconia (YZ – IPS e.max ZirCAD, Ivoclar), lithium disilicate (LD – IPS e.max CAD, Ivoclar) and polymer infiltrated ceramic network (PICN – Enamic, Vita Zahnfabrik). The crowns were allocated considering two factors: 'substrate' (epoxy resin or cast Ni-Cr metal core) and 'occlusal contact pattern' (contact at the cusp ridges or cusp tips). The substrate models were design, milled and scanned to plan the restorations in a digital workflow. The crowns were milled, bonded to the substrates, and subjected to an accelerated fatigue test (100 N; 10,000 cycles/step; 20 Hz step-size: 100 N up to 1600 N, and after, 200 N until failure or survival at 2,800N; immersed in water). Statistical analyses were performed using two-way ANOVA, Tukey's post-hoc test, and Kaplan-Meier survival analysis (α = 0.05) considering fatigue failure load and cycles for fatigue failure (FFL/CFF). Fractographic and finite element analysis (FEA) were carried out. The results indicate that the 'substrate' factor did not influence the mechanical behavior of YZ and LD monolithic crowns (p > 0.05). However, PICN crowns bonded to epoxy resin exhibited statistically superior results for FFL and CFF (p < 0.05) compared to Ni-Cr cores. Regarding the 'occlusal contact pattern' factor, YZ and LD exhibited higher mean FFL and CFF when associated with cusp tip contact compared to cusp ridge contact (p < 0.05), except for YZ bonded to the epoxy resin substrate (p > 0.05). No differences were detected for the 'occlusal contact' factor in PICN crowns (p > 0.05). The predominant failure was Hertzian cone cracks, regardless of the restorative material. Stress measurements showed higher stress peaks at the cusp ridges. The core material did not alter the fatigue mechanical behavior of YZ or LD crowns. However, the incidence of cusp ridge contacts in YZ or LD crown increases the risk of failure. Conversely, when using PICN crowns, a core with a more similar elastic modulus enhances mechanical behavior compared to a stiffer core, and no influence on the occlusal pattern was observed.

Original language	English
Article number	106891
Pages (from-to)	1-14
Number of pages	14
Journal	Journal of the Mechanical Behavior of Biomedical Materials
Volume	163
Early online date	9 Jan 2025
DOIs	https://doi.org/10.1016/j.jmbbm.2025.106891
Publication status	Published - Mar 2025

Bibliographical note

Publisher Copyright:
© 2025 The Authors

Funding

This work is part of the fulfillment of the requirements of the MSci degree (M.G.P.) in the Post-Graduate Program in Oral Sciences at the Faculty of Dentistry, Federal University of Santa Maria. This research was partially financed by the Brazilian Federal Agency for Coordination of Improvement of Higher Education Personnel – CAPES, (Finance code 001 for M.G.P. Master's scholarship); by the Brazilian National Council for Scientific and Technological Development – CNPq (#442272/2023-5 related to the CNPq Call 14/2023 - Support for International Scientific, Technological and Innovation Research Projects; #151004/2022-6 for R.V.M. Post-doctoral scholarship; #304665/2022-3 for G.K.R.P research grant; and #308427/2021-1 for L.F.V research grant); and by Ivoclar by donating research materials used. We emphasize that the aforementioned institutions did not have any role in the study design, data collection or analysis, decision to publish, or in preparing the manuscript. This work is part of the fulfillment of the requirements of the MSci degree (M.G.P.) in the Post-Graduate Program in Oral Sciences at the Faculty of Dentistry, Federal University of Santa Maria. This research was partially financed by the Brazilian Federal Agency for Coordination of Improvement of Higher Education Personnel – CAPES, (Finance code 001 for M.G.P. Master’s scholarship); by the Brazilian National Council for Scientific and Technological Development – CNPq (#442272/2023-5 related to the CNPq Call 14/2023 - Support for International Scientific, Technological and Innovation Research Projects; #151004/2022-6 for R.V.M. Post-doctoral scholarship; #304665/2022-3 for G.K.R.P research grant; and #308427/2021-1 for L.F.V research grant); and by Ivoclar by donating research materials used. We emphasize that the aforementioned institutions did not have any role in the study design, data collection or analysis, decision to publish, or in preparing the manuscript.

Funders	Funder number
Universidade Federal de Santa Maria
Brazilian Federal Agency for Coordination of Improvement of Higher Education Personnel
Coordenação de Aperfeiçoamento de Pessoal de Nível Superior
MSci degree
Conselho Nacional de Desenvolvimento Científico e Tecnológico	151004/2022-6, 304665/2022-3, 442272/2023, 308427/2021-1

Keywords

Dental ceramics
Fatigue
Finite element analysis
Mechanical phenomena
Survival

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10.1016/j.jmbbm.2025.106891

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Cite this

Packaeser, M. G., Machry, R. V., Grassi, E. D. A., Saavedra, G. D. S. F. A., Kleverlaan, C. J., Valandro, L. F., Tribst, J. P. M., & Pereira, G. K. R. (2025). Influence of core material and occlusal contact pattern on fatigue behavior of different monolithic ceramic crowns. Journal of the Mechanical Behavior of Biomedical Materials, 163, 1-14. Article 106891. https://doi.org/10.1016/j.jmbbm.2025.106891

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title = "Influence of core material and occlusal contact pattern on fatigue behavior of different monolithic ceramic crowns",

abstract = "This study evaluated the effect of substrate core materials and occlusal contact patterns on the fatigue mechanical behavior and stress distribution of single-unit ceramic crowns. One hundred and twenty monolithic crowns were fabricated from zirconia (YZ – IPS e.max ZirCAD, Ivoclar), lithium disilicate (LD – IPS e.max CAD, Ivoclar) and polymer infiltrated ceramic network (PICN – Enamic, Vita Zahnfabrik). The crowns were allocated considering two factors: 'substrate' (epoxy resin or cast Ni-Cr metal core) and 'occlusal contact pattern' (contact at the cusp ridges or cusp tips). The substrate models were design, milled and scanned to plan the restorations in a digital workflow. The crowns were milled, bonded to the substrates, and subjected to an accelerated fatigue test (100 N; 10,000 cycles/step; 20 Hz step-size: 100 N up to 1600 N, and after, 200 N until failure or survival at 2,800N; immersed in water). Statistical analyses were performed using two-way ANOVA, Tukey's post-hoc test, and Kaplan-Meier survival analysis (α = 0.05) considering fatigue failure load and cycles for fatigue failure (FFL/CFF). Fractographic and finite element analysis (FEA) were carried out. The results indicate that the 'substrate' factor did not influence the mechanical behavior of YZ and LD monolithic crowns (p > 0.05). However, PICN crowns bonded to epoxy resin exhibited statistically superior results for FFL and CFF (p < 0.05) compared to Ni-Cr cores. Regarding the 'occlusal contact pattern' factor, YZ and LD exhibited higher mean FFL and CFF when associated with cusp tip contact compared to cusp ridge contact (p < 0.05), except for YZ bonded to the epoxy resin substrate (p > 0.05). No differences were detected for the 'occlusal contact' factor in PICN crowns (p > 0.05). The predominant failure was Hertzian cone cracks, regardless of the restorative material. Stress measurements showed higher stress peaks at the cusp ridges. The core material did not alter the fatigue mechanical behavior of YZ or LD crowns. However, the incidence of cusp ridge contacts in YZ or LD crown increases the risk of failure. Conversely, when using PICN crowns, a core with a more similar elastic modulus enhances mechanical behavior compared to a stiffer core, and no influence on the occlusal pattern was observed.",

keywords = "Dental ceramics, Fatigue, Finite element analysis, Mechanical phenomena, Survival",

author = "Packaeser, \{Maria Gabriela\} and Machry, \{Renan Vaz\} and Grassi, \{Elisa Donaria Aboucauch\} and Saavedra, \{Guilherme de Siqueira Ferreira Anzaloni\} and Kleverlaan, \{Cornelis Johannes\} and Valandro, \{Luiz Felipe\} and Tribst, \{Jo{\~a}o Paulo Mendes\} and Pereira, \{Gabriel Kalil Rocha\}",

note = "Publisher Copyright: {\textcopyright} 2025 The Authors",

year = "2025",

month = mar,

doi = "10.1016/j.jmbbm.2025.106891",

language = "English",

volume = "163",

pages = "1--14",

journal = "Journal of the Mechanical Behavior of Biomedical Materials",

issn = "1751-6161",

publisher = "Elsevier Ltd",

}

Influence of core material and occlusal contact pattern on fatigue behavior of different monolithic ceramic crowns. / Packaeser, Maria Gabriela; Machry, Renan Vaz; Grassi, Elisa Donaria Aboucauch et al.
In: Journal of the Mechanical Behavior of Biomedical Materials, Vol. 163, 106891, 03.2025, p. 1-14.

Research output: Contribution to Journal › Article › Academic › peer-review

TY - JOUR

T1 - Influence of core material and occlusal contact pattern on fatigue behavior of different monolithic ceramic crowns

AU - Packaeser, Maria Gabriela

AU - Machry, Renan Vaz

AU - Grassi, Elisa Donaria Aboucauch

AU - Saavedra, Guilherme de Siqueira Ferreira Anzaloni

AU - Kleverlaan, Cornelis Johannes

AU - Valandro, Luiz Felipe

AU - Tribst, João Paulo Mendes

AU - Pereira, Gabriel Kalil Rocha

PY - 2025/3

Y1 - 2025/3

N2 - This study evaluated the effect of substrate core materials and occlusal contact patterns on the fatigue mechanical behavior and stress distribution of single-unit ceramic crowns. One hundred and twenty monolithic crowns were fabricated from zirconia (YZ – IPS e.max ZirCAD, Ivoclar), lithium disilicate (LD – IPS e.max CAD, Ivoclar) and polymer infiltrated ceramic network (PICN – Enamic, Vita Zahnfabrik). The crowns were allocated considering two factors: 'substrate' (epoxy resin or cast Ni-Cr metal core) and 'occlusal contact pattern' (contact at the cusp ridges or cusp tips). The substrate models were design, milled and scanned to plan the restorations in a digital workflow. The crowns were milled, bonded to the substrates, and subjected to an accelerated fatigue test (100 N; 10,000 cycles/step; 20 Hz step-size: 100 N up to 1600 N, and after, 200 N until failure or survival at 2,800N; immersed in water). Statistical analyses were performed using two-way ANOVA, Tukey's post-hoc test, and Kaplan-Meier survival analysis (α = 0.05) considering fatigue failure load and cycles for fatigue failure (FFL/CFF). Fractographic and finite element analysis (FEA) were carried out. The results indicate that the 'substrate' factor did not influence the mechanical behavior of YZ and LD monolithic crowns (p > 0.05). However, PICN crowns bonded to epoxy resin exhibited statistically superior results for FFL and CFF (p < 0.05) compared to Ni-Cr cores. Regarding the 'occlusal contact pattern' factor, YZ and LD exhibited higher mean FFL and CFF when associated with cusp tip contact compared to cusp ridge contact (p < 0.05), except for YZ bonded to the epoxy resin substrate (p > 0.05). No differences were detected for the 'occlusal contact' factor in PICN crowns (p > 0.05). The predominant failure was Hertzian cone cracks, regardless of the restorative material. Stress measurements showed higher stress peaks at the cusp ridges. The core material did not alter the fatigue mechanical behavior of YZ or LD crowns. However, the incidence of cusp ridge contacts in YZ or LD crown increases the risk of failure. Conversely, when using PICN crowns, a core with a more similar elastic modulus enhances mechanical behavior compared to a stiffer core, and no influence on the occlusal pattern was observed.

AB - This study evaluated the effect of substrate core materials and occlusal contact patterns on the fatigue mechanical behavior and stress distribution of single-unit ceramic crowns. One hundred and twenty monolithic crowns were fabricated from zirconia (YZ – IPS e.max ZirCAD, Ivoclar), lithium disilicate (LD – IPS e.max CAD, Ivoclar) and polymer infiltrated ceramic network (PICN – Enamic, Vita Zahnfabrik). The crowns were allocated considering two factors: 'substrate' (epoxy resin or cast Ni-Cr metal core) and 'occlusal contact pattern' (contact at the cusp ridges or cusp tips). The substrate models were design, milled and scanned to plan the restorations in a digital workflow. The crowns were milled, bonded to the substrates, and subjected to an accelerated fatigue test (100 N; 10,000 cycles/step; 20 Hz step-size: 100 N up to 1600 N, and after, 200 N until failure or survival at 2,800N; immersed in water). Statistical analyses were performed using two-way ANOVA, Tukey's post-hoc test, and Kaplan-Meier survival analysis (α = 0.05) considering fatigue failure load and cycles for fatigue failure (FFL/CFF). Fractographic and finite element analysis (FEA) were carried out. The results indicate that the 'substrate' factor did not influence the mechanical behavior of YZ and LD monolithic crowns (p > 0.05). However, PICN crowns bonded to epoxy resin exhibited statistically superior results for FFL and CFF (p < 0.05) compared to Ni-Cr cores. Regarding the 'occlusal contact pattern' factor, YZ and LD exhibited higher mean FFL and CFF when associated with cusp tip contact compared to cusp ridge contact (p < 0.05), except for YZ bonded to the epoxy resin substrate (p > 0.05). No differences were detected for the 'occlusal contact' factor in PICN crowns (p > 0.05). The predominant failure was Hertzian cone cracks, regardless of the restorative material. Stress measurements showed higher stress peaks at the cusp ridges. The core material did not alter the fatigue mechanical behavior of YZ or LD crowns. However, the incidence of cusp ridge contacts in YZ or LD crown increases the risk of failure. Conversely, when using PICN crowns, a core with a more similar elastic modulus enhances mechanical behavior compared to a stiffer core, and no influence on the occlusal pattern was observed.

KW - Dental ceramics

KW - Fatigue

KW - Finite element analysis

KW - Mechanical phenomena

KW - Survival

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U2 - 10.1016/j.jmbbm.2025.106891

DO - 10.1016/j.jmbbm.2025.106891

M3 - Article

AN - SCOPUS:85215105689

SN - 1751-6161

VL - 163

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JO - Journal of the Mechanical Behavior of Biomedical Materials

JF - Journal of the Mechanical Behavior of Biomedical Materials

M1 - 106891

ER -

Influence of core material and occlusal contact pattern on fatigue behavior of different monolithic ceramic crowns

Abstract

Bibliographical note

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Keywords

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