Pµsl Fabricates Ultra-Thin And Tough Zirconia Veneers

To evaluate the feasibility of PµSL technology in fabricating ultra-thin (80 μm) zirconia veneers, optimizing printing parameters for enhanced precision, mechanical strength, and clinical applicability, while minimizing tooth preparation. A PµSL system with oxygen-permeable films was employed to mitigate light scattering and improve curing accuracy. Zirconia slurry (80 wt%) was used, with parameters optimized (exposure intensity: 50 mW/cm², layer thickness: 20 μm). Post-processing included debinding and sintering. Comparative analyses with CNC-milled veneers (500 μm) assessed accuracy, marginal fit, and mechanical performance. PµSL-produced 80 μm thick zirconia veneers achieved superior accuracy (RMS: 20.4 ± 1.3 μm vs. 31.8 ± 2.2 μm for milled) and marginal fit (27.28 ± 6.22 μm vs. 72.80 ± 46.59 μm). Compression tests showed comparable strength (31.2 ± 2.6 N vs. 34.9 ± 4.7 N for 500 μm milled lithium disilicate veneers). Sintered zirconia exhibited uniform microstructure (grain size: ∼0.55 μm) and high density. PµSL enables high-precision, ultra-thin zirconia veneers with clinical-grade mechanical properties, reducing tooth preparation and enhancing biocompatibility. This technology offers a minimally invasive solution for aesthetic and functional dental restoration.