Er:YAG Laser Removal of Implant-Supported Digitally Manufactured Single Crowns Made of Lithium Disilicate: Influence of Crown Spacer and Abutment Taper

Background/Objectives: The purpose of this study was to investigate the laser removal of implant-supported ceramic single crowns, focusing on their efficiency and the potential reusability of the removed restorations. Methods: Sixty single crowns made of lithium disilicate were adhesively bonded to prefabricated titanium abutments in a total of six test series (n = 10). The test series were divided according to the different spacer settings of the crowns (90 µm, 120 µm, 150 µm) and the taper of the abutments (4°, 6°). After seven days of storage in distilled water, the single crowns were removed using an erbium-doped yttrium aluminium garnet (Er:YAG) laser. The number of laser pulses needed and the time required to remove the crowns were recorded. This was followed by a micro- and macroscopic score evaluation of the crowns using a fluorescent penetration method. Results: Laser removal of all sixty crowns was successfully performed. Using a taper of 6° and a spacer of 150 µm, the crowns were removed with significantly fewer pulses (61.40 (±36.78)). The taper and spacer had a significant effect on both the microscopic (p = 0.040) and macroscopic (p = 0.035) fracture patterns. Based on the final score of the fracture analysis, 44 of the 60 crowns could be classified as potentially reusable. The remaining 16 crowns failed due to purely macroscopic (7), purely microscopic (6), and combined microscopic and macroscopic (3) fracture behavior. Conclusions: Based on the results of this study, increasing the size of the taper and spacer has proven beneficial for laser removal in terms of time efficiency and non-destructive removal of crowns.