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<p><?tk 4?>The application of ceramic three-dimensional (3D) printing in dentistry requires effective control of volume shrinkage and structural deformation during sintering. The optimum sintering conditions of the specimen and mixing ratio of zirconia in the slurry were determined to evaluate and compare the physical and mechanical properties of zirconia specimens fabricated using the dual method of gel casting and photocuring under different sintering conditions. Zirconia specimens were fabricated using a dual approach that combined gel casting with digital light processing (DLP) photocuring and were subjected to different sintering conditions (speed sintering, two-step sintering, and conventional sintering) with varying zirconia contents (50%, 55%, and 60%). Disk-shaped specimens (20&#xa0;mm × 2&#xa0;mm) were divided into nine groups (n = 50) and evaluated for physical properties (linear shrinkage, dried and sintered density, SEM, XRD, and EDS analyses) and mechanical properties (Vickers hardness, fracture toughness, and biaxial flexural strength). The reliability of biaxial flexural strength was further analyzed using Weibull distribution. Among all groups, the specimens containing 55% zirconia under two-step sintering (TSS) conditions exhibited superior mechanical performance. Furthermore, the mechanical properties improved with increasing zirconia volume fraction, and the biaxial flexural strengths of the TSS groups were significantly higher than those of the speed-sintered (SS) groups.</p> Graphical abstract <p></p> <p>Dual processing of gel casting and 3D printing enables the fabrication of customized zirconia prostheses with improved densification and mechanical properties.</p>

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Fabrication of tailor-made zirconia dental prostheses via dual processing of gel casting and 3D printing

  • 期刊论文

  • 发表日期：

    2025年12月15日

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  • Woo-Chang Kwon,
  • Soojung Lee,
  • Chiho Moon,
  • Ildoo Chung

摘要

The application of ceramic three-dimensional (3D) printing in dentistry requires effective control of volume shrinkage and structural deformation during sintering. The optimum sintering conditions of the specimen and mixing ratio of zirconia in the slurry were determined to evaluate and compare the physical and mechanical properties of zirconia specimens fabricated using the dual method of gel casting and photocuring under different sintering conditions. Zirconia specimens were fabricated using a dual approach that combined gel casting with digital light processing (DLP) photocuring and were subjected to different sintering conditions (speed sintering, two-step sintering, and conventional sintering) with varying zirconia contents (50%, 55%, and 60%). Disk-shaped specimens (20 mm × 2 mm) were divided into nine groups (n = 50) and evaluated for physical properties (linear shrinkage, dried and sintered density, SEM, XRD, and EDS analyses) and mechanical properties (Vickers hardness, fracture toughness, and biaxial flexural strength). The reliability of biaxial flexural strength was further analyzed using Weibull distribution. Among all groups, the specimens containing 55% zirconia under two-step sintering (TSS) conditions exhibited superior mechanical performance. Furthermore, the mechanical properties improved with increasing zirconia volume fraction, and the biaxial flexural strengths of the TSS groups were significantly higher than those of the speed-sintered (SS) groups.

Graphical abstract

Dual processing of gel casting and 3D printing enables the fabrication of customized zirconia prostheses with improved densification and mechanical properties.