Impact of Thermomechanical Aging on Marginal Fit and Fracture Resistance of CAD/CAM Endocrowns Fabricated from Different Materials

The restoration of endodontically treated teeth remains a clinical challenge, particularly when substantial coronal tissue loss is present. Endocrowns fabricated using CAD/CAM technologies offer a conservative and esthetic alternative to conventional post-core systems; however, their long-term performance may be influenced by age-related mechanical and thermal stresses. This study evaluated the effect of thermomechanical aging on the marginal adaptation and fracture resistance of endocrowns fabricated from three CAD/CAM materials: zirconia-reinforced lithium silicate (ZLS), polyetherether ketone (PEEK), and 3D-printed resin. Sixty extracted human molars were endodontically treated and restored with endocrowns produced from these materials (<i>n</i> = 20 per group) and then subdivided into aged (<i>n</i> = 10) and control (<i>n</i> = 10) subgroups. Thermomechanical aging involved 5000 thermal cycles between 5 °C and 55 °C, and 75,000 mechanical loading cycles at 50 N. Marginal gaps were examined using scanning electron microscopy, and fracture resistance was tested under axial load at a crosshead speed of 0.5 mm/min. Data were analyzed using two-way ANOVA followed by Tukey's post hoc test (α = 0.05). Thermomechanical aging significantly increased the marginal gaps in all materials (<i>p</i> < 0.05). The smallest marginal discrepancies were observed in the 3D-printed resin group, while the largest occurred in the ZLS after aging, likely due to dimensional changes during crystallization. Fracture resistance decreased in ZLS (-21.2%) and 3D resin (-20.9%) after aging (<i>p</i> < 0.05) but was not significantly affected in PEEK (-5.4%, <i>p</i> = 0.092). Thermomechanical aging adversely affects marginal adaptation across all materials, whereas its impact on strength is material-dependent. PEEK demonstrated the most stable mechanical performance and may represent a promising alternative for long-term endocrown restorations.