Sintering distortion of monolithic zirconia in 4-unit fixed partial denture: Effect of layered structure and vertical milling area

Layered-type zirconia disks, which offer color gradation from enamel to cervical shade, have been employed in recent years to replicate the shades of natural teeth. The layered structure is effective at replicating colors and has helped popularize monolithic zirconia restorations. However, the sintering shrinkage of zirconia is very large; thus, controlling the sintering distortion is very important. Thus, the objective of this study was to determine the influence exerted by the layered structure of the zirconia disk and the vertical milling area on the sintering distortion. An experimental fixed partial denture (FPD) was designed based on a 4-unit monolithic zirconia FPD. A single-composition (SC)-type disk with no shade and a single-composition-layered (SCL)-type disk with shade gradation were selected for this study. In particular, three milling areas, the top end of the disk (area I), vertical center (area II), and bottom end of the disk (area III), were investigated. Moreover, the sintering distortions generated by the experimental FPDs were measured. Results showed that sintering distortion in 4-unit monolithic zirconia FPDs occurred in all SC and SCL areas. Additionally, the sintering distortions were affected by the layered structure of the zirconia disks, the degree of which depended on the milling area (area I > area II > area III). Thus, when fabricating dental prosthesis using SCL zirconia disks, the milling area must be selected considering both the color adjustment and sintering distortion.