Thickness and Substrate Effect on the Mechanical Behaviour of Direct Occlusal Veneers

Purpose: This study aimed to evaluate the fracture resistance and stress magnitude of occlusal veneers made of conventional or flowable resin composites at different minimal thicknesses bonded on enamel or dentin. Material and methods: A total of 120 sound bovine incisors were flattened and used as substrates (enamel or dentin) for the restorations. The teeth were embedded into polymethyl methacrylate and allocated into 4 groups according to the resin composite (Clearfil AP-X PLT and Clearfil Majesty Flow, Kuraray Dental) and substrate. Further, the substrates were randomly subdivided in 12 groups (N = 120, n = 10) according to the occlusal veneer minimal thickness: 0.5, 1.0, or 2.0 mm. The teeth were directly restored with a standardised procedure. Then, the specimens were loaded until fracture in a universal testing machine (Instron 6022, Instron Corp.). A 3-way and a 1-way analysis of variance were used to determine significant differences for each factor. Three-dimensional finite element analysis was carried out following the in vitro boundary conditions to assess the stress magnitude in the restoration during compressive loading. Results: The fracture loads were recorded into initial load to failure (ILF) and fatal load to failure (FLF). Differences were found in material for ILF and FLF, leading to an overall equal good performance in fracture load and stress distribution for both materials, regardless of the substrate. Differences in thickness were apparent in both ILF and FLF. Conclusions: Direct conventional and flow resin composite occlusal veneers present a promising mechanical behaviour when bonded on enamel or dentin. However, caution is advised when preparing 0.5-mm minimal thickness restorations.