Effect of material thickness on the fracture resistance and failure pattern of 3D-printed composite crowns

Aim: To evaluate the fracture resistance and failure pattern of 3D-printed and milled composite resin crowns as a function of different material thicknesses. Materials and methods: Three typodont tooth models were prepared to receive a full coverage composite resin crown with different thicknesses (0.5, 1.0, and 1.5 mm). The prepared master casts were digitally scanned using an intraoral scanner, and the STL files were used to fabricate 60 nanocomposite crowns divided into two groups according to the material thickness (n = 10) and fabrication method: a 3D-printed group (3D) using an SLA printer with nanocomposite, and a milled group (M) using a milling machine and composite blocks. All crowns were adhesively seated on stereolithography (SLA)-fabricated dies. All samples were subjected to thermomechanical loading and fracture testing. The load to fracture [N] was recorded and the failure pattern evaluated. Data were statistically analyzed using a two-way ANOVA followed by a Bonferroni post hoc test. The level of significance was set at α = 0.05. Results: The 3D group showed the highest values for fracture resistance compared with the milled group within the three tested thicknesses (P 0.001). The 3D and M groups presented significantly higher load to fracture for the 1.5-mm thickness (2383.5 ± 188.58 N and 1284.7 ± 77.62 N, respectively) compared with the 1.0-mm thickness (1945.9 ± 65.32 N and 932.1 ± 41.29 N, respectively) and the 0.5-mm thickness, which showed the lowest values in both groups (1345.0 ± 101.15 N and 519.3 ± 32.96 N, respectively). A higher incidence of irreparable fractures was observed for the 1.5-mm thickness. Conclusion: 3D-printed composite resin crowns showed high fracture resistance at different material thicknesses and can be suggested as a viable solution in conservative dentistry. Keywords: additive manufacturing, 3D printing, composite crowns, CAD/CAM, fracture resistance, failure pattern