Individualisation of monolithic zirconia restorations

Article by Dr. Florian Zwiener

Modern multi-layered zirconia such as KATANA™ Zirconia STML (Kuraray Noritake Dental Inc.) already meets high aesthetic demands due to its natural colour gradient and high translucency. To achieve further characterisation and optical adjustment to the adjacent teeth, there are essentially two options: veneering with feldspathic ceramic or glazing and individualisation with ceramic stains.

While there are still many indications for veneering, especially in the anterior area, more and more cases can now be solved with monolithic restorations. This allows for a time-efficient chairside workflow with same-day treatment, eliminating the need for temporary restorations. Additionally, the absence of a porcelain layer reduces the wall thickness of the restoration and thus the space required, allowing for less invasive preparation. This also reduces the risk of endodontic complications induced by tooth preparation (grinding trauma). Another advantage is a significant reduction in the chipping risk.

Below are the essential steps for individualisation using ceramic stains, demonstrated through the example of a molar crown.

PREPARATION

The restoration is designed in full contour as usual, ideally dry-milled, and then sintered. After sintering, the restoration is first sandblasted (aluminium oxide 50 μm, 1 to 1.5 bar pressure). This microscopic roughening of the ceramic surface enables an optimal bond with the glaze. Subsequently, the restoration should be cleaned using a steam cleaner or an ultrasonic cleaner to remove all blasting residue.

The functional restoration surfaces must then be polished to avoid the risk of excessive abrasion on the enamel of the opposing dentition, as zirconia is harder than enamel. Following this, optional glazing and characterization with ceramic stains can be performed. However, for areas not in the aesthetic zone, such as the palatal surfaces of maxillary anterior teeth, this is not necessarily required.

PREPARATION: STEPS AT A GLANCE

1. Sandblasting of the sintered restoration (Al2O3 50 μm, 1-1.5 bar)
2. Cleaning (steam cleaner or ultrasonic cleaner)
3. Polishing the occlusal/palatal contact areas

Fig. 1. Sintered and sandblasted zirconia crown.

Fig. 2. Occlusal high-gloss polish.

Fig. 3. TWIST™ DIA for Zirconia (Kuraray Noritake Dental Inc.) enables efficient polishing of zirconia in three steps.

STAINING AND GLAZING

The shades A+, B+, C+, and D+ of the paste-like ceramic stain CERABIEN™ ZR FC Paste Stain (Kuraray Noritake Dental Inc.) enhance the chroma in the cervical area when applied in the respective tooth shade. They are used to strengthen the multicolour effect of the zirconia or to darken the restoration overall. By mixing the stains with glaze or clear glaze in different ratios, the intensity can be adjusted.

Cervical 1 and 2 are suitable for replicating exposed cervical areas or discolouration. Cervical 1 is also useful for marking fissures, as it gives the crown depth and structure without appearing overly dark. Patients typically reject excessively pronounced fissure effects. Since fissure areas in multi-layered materials generally lie in the lightest part of the block (in the enamel layer), it may make sense to darken them slightly with A+, while white hypermineralisations can be replicated on the cusp tips. A narrow band of Grayish Blue below the cusp tips creates an optical translucency effect. In cases where this translucency appears too dark blue or greyish, mixing Grayish Blue with Dark Grey can modify the appearance.

By mixing various colours, numerous different tones can be created. For instance, by adding Yellow to A+, its slightly brownish colour can be adjusted to a warmer, more yellowish tooth shade. It is generally advisable to capture the patient‘s tooth shade with a photo and a custom-made colour ring of the corresponding material before preparation. This can serve as a reference during production, especially in the laboratory, where lighting conditions may differ.

For pronounced characterisations or fine details, it may be necessary to carry out multiple firings to avoid unwanted running effects between the colours and the glaze. This is particularly recommended when replicating anatomical details with high sharpness, such as enamel cracks or local discolourations. For this, a glaze and base shade are first applied and fired, and finer structures are added in a second firing. Alternatively, a fixative firing of the stains without glaze can be performed first, with only a glaze layer fired in the second step. A benefit of CERABIEN™ ZR FC Paste Stain is that its appearance during application closely matches the final firing result. In thick consistency, glaze can also be used to easily rebuild missing proximal contacts.

STAINING AND GLAZING: STEPS AT A GLANCE

1. Glaze with Glaze/Clear Glaze
2. Increase chroma (in the cervical area or over large areas) with A+, B+, C+, or D+
   - Adjust intensity by mixing with Glaze/Clear Glaze
   - Create a warmer tone by mixing with Yellow
3. Replicate discolouration/exposed cervical areas: Cervical 1 and 2
4. Customise fissure areas
   - Darken with A+, B+, C+, or D+
   - Accentuate fissures with Cervical 1
5. Customise cusp tips
   - Replicate hypermineralisations with White
   - Create a band below with Grayish Blue (translucency effect)
   - Adjust translucency effect below cusp tips by mixing with Dark Grey
6. Firing

Alternatives:

1. First firing: Glaze plus base shade, second firing: Finer structures
2. First firing: Fixative stain firing without glaze, second firing: Glaze firing

Fig. 4. CERABIEN™ ZR FC Paste Stain assortment for the practice laboratory.

Fig. 5. Discoloured fissures can be accurately replicated with an ISO10 endodontic file.

Fig. 6 and 7. Glazing and staining in one firing.

Fig. 8. Shade determination using a custom-made KATANA™ Zirconia STML colour ring (A3.5).

Fig. 9. Bridge made from KATANA™ Zirconia STML, sandblasted and occlusally polished.

Fig. 10. Finished glazed and characterised restoration.

Fig. 11. Bridge 14-16 in place.

FINAL SITUATION

Fig. 11. Bridge 14-16 in place.

Dentist:

FLORIAN ZWIENER

• 10. dets 2024

CERABIEN ZR FC Paste Stain Vaata toodet

KATANA Zirconia Block Vaata toodet