Assessing Ideal Die Spacer Parameters for Zirconia Crowns: Addressing Fitting Challenges while Converting from Physical Stone Models to Digital Printed Models

This study investigates the impact of die spacer thickness on the accuracy of zirconia crown fabrication using both traditional stone and 3D printed resin models. Zirconia crowns were manufactured with three die spacer settings 20 ?m, 40 ?m, and 60 ?m for single - unit and three - unit bridges. Using traditional marginal gap measurements and advanced superimposition analysis in Exocad software, the results showed that a 40 ?m die spacer provided the best marginal fit and contact accuracy across both model types. The study highlights the importance of combining traditional evaluation methods with advanced digital tools to optimize the fabrication process. These findings provide valuable insights for dental labs transitioning to digital workflows to improve zirconia crown precision and fit.