Weibull-Based Reliability of Full-Arch Zirconia Prostheses in a Mandibular All-on-4 Model: Monolithic Versus Titanium-Bar-Supported Designs

Full-arch zirconia prostheses for mandibular All-on-4 rehabilitations are provided as screw-retained monolithic zirconia (Zr-Mono) or as a zirconia suprastructure luted to a CAD/CAM titanium bar (Zr-TiBar). Because zirconia is a brittle and flaw-sensitive ceramic, design assessment should incorporate stress-field-weighted fracture risk. This in silico study compared zirconia tensile stress, deformation, and Weibull-based reliability between Zr-Mono and Zr-TiBar designs in a standardized edentulous mandibular All-on-4 model (posterior implants tilted 30°) using linear static finite element analysis. Accordingly, 300 N posterior unilateral loads were applied at the first molar (axial; 45° oblique). Outcomes were maximum principal tensile stress in zirconia (S1max), total prosthesis deformation, and Weibull-predicted fracture probability (Pf) derived from the tensile S1 field. Under axial loading, S1max was essentially identical between designs (~277 MPa). Under oblique loading, S1max was modestly lower for Zr-TiBar (~227 MPa) than for Zr-Mono (~234 MPa), and deformation was slightly lower for Zr-TiBar (<0.07 mm in all cases). Pf remained very low for both designs (10−6–10−7 range) and differed only slightly between them. Under the modeled single 300 N posterior load case, the titanium-bar support reduced deformation and modestly reduced oblique-load peak tensile stress but did not materially reduce the predicted zirconia Pf compared with monolithic zirconia.