Zirconia specimens printed by vat photopolymerization: Mechanical properties, fatigue properties, and fractography analysis

Abstract Purpose The mechanical and fatigue properties of zirconia specimens printed by vat photopolymerization (VPP) were evaluated and compared with those of zirconia specimens milled by computer numerical control (CNC). Materials and Methods Bar‐shaped specimens were printed by stereolithography (SL) and digital light processing (DLP). CNC‐milled specimens were used as control samples. The fracture toughness, hardness, and flexural strength properties of the zirconia specimens were evaluated via single edge V‐notch beam tests, Vickers hardness tests, and 3‐point bending tests. Dynamic fatigue tests were carried out in distilled water using a step‐stress test. After static bending and dynamic step‐stress testing, fractography analysis was performed. Statistical analysis was carried out to compare the fracture toughness, hardness, flexural strength, and fatigue cycle results of each group ( α = 0.05). Results The fracture toughness values did not significantly differ among the groups ( p > 0.05). The flexural strength was 894.10 MPa for SL, 831.46 MPa for DLP, and 1140.39 MPa for CNC. The flexural strength of CNC was greater than that of SL and DLP ( p < 0.01). The mean fatigue cycles were 23498.07 for SL, 19858.60 for DLP, and 31566.80 for CNC. The mean fatigue failure strength was 643.13 MPa for SL, 530.63 MPa for DLP, and 903.75 MPa for CNC. The fatigue failure strength of CNC was greater than that of SL and DLP ( p < 0.05). Fractography analysis revealed material defects at the fracture origin for each group. A partially fused structure of the incompletely debonded resin could be observed in SL, and a porous region of incompletely sintered zirconia grains could be observed in CNC. Conclusions The fracture toughness and hardness of zirconia printed by VPP are comparable to those of zirconia milled by CNC. However, zirconia milled by CNC has superior static flexural strength and dynamic fatigue resistance. Further studies are needed to explore the clinical applications of VPP‐printed zirconia.