Micropatterned Zirconia Veneers For Discolored Anterior Restorations

This case report explores the application of 3D-printed zirconia veneers with micropatterned bonding surfaces to improve the adhesive durability of restorations for discolored anterior teeth, highlighting a minimally invasive approach integrating digital workflows and surface engineering. A 49-year-old female model presented with discolored resin restorations on teeth #15–25. Clinical examination revealed marginal staining and partial restoration failure. A conservative treatment strategy was adopted, utilizing digital workflows with TRIOS scanning and exocad software to design zirconia veneers (0.5 mm thickness, 65 μm cement space) with open-edge margins. The bonding surfaces of the 3D-printed zirconia veneers (ACJ technology, Tally Medical, China) were engineered with uniformly distributed square micropores (100×100 μm) to enhance adhesive retention. Surface pretreatment involved sandblasting with 50 μm Al₂O₃ followed by the application of a zirconia primer. Adhesive cementation was performed using dual-cure resin cement under rubber dam isolation. A two-week postoperative assessment demonstrated optimal marginal adaptation, color integration, and gingival health. Bonding conventional zirconia restorations presents challenges such as phase transformation and limited resin infiltration. The integration of micropatterning and chemical priming significantly improved adhesion, yielding bond strengths comparable to glass ceramics. Additionally, the digital workflow minimized chairside time while enhancing precision. This case highlights the efficacy of 3D-printed micropatterned zirconia veneers in addressing aesthetic challenges. The combination of digital design, surface micropatterning, and adhesive protocols offers a minimally invasive, patient-specific solution, advancing the field of aesthetic dentistry.