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Research Article: Comparison of surface integrity, longevity of posterior tooth-colored crowns fabricated by conventional, CAD/CAM, and 3D printing techniques

Date Published: 2026-08-18

Abstract:
This in vitro study evaluated internal and marginal surface roughness and simulated thermocycling survival of posterior tooth-colored crowns fabricated using conventional laboratory, CAD/CAM milling, and digital light processing 3D printing workflows. The roughness analysis included 46 crowns allocated to six groups: lab-made crowns ( n =?6), IPS e.max CAD ( n =?8), IPS Empress CAD ( n =?8), Lava Ultimate ( n =?8), IPS e.max ZirCAD ( n =?8), and 3 D SprintRay Ceramic ( n =?8). Internal and marginal arithmetic mean roughness (Ra, µm) were measured with a 3D non-contact profilometer. Because residual normality and variance homogeneity assumptions were not satisfied, group differences were analyzed using Kruskal–Wallis tests followed by Holm-adjusted pairwise Mann–Whitney U tests. Internal Ra differed significantly among groups ( H =?25.76, df?=?5, p <?0.001). 3D printed SprintRay Ceramic showed the highest internal Ra (29.27?±?5.45?µm) and was significantly rougher internally than every other group after Holm correction. Marginal Ra also differed significantly among groups ( H =?41.86, df?=?5, p <?0.001). IPS e.max CAD showed the highest marginal Ra (26.81?±?1.73?µm), followed by lab-made crowns (19.31?±?6.40?µm), whereas IPS e.max ZirCAD showed the lowest marginal Ra (4.82?±?1.03?µm). Within the limitation of the present study material type and fabrication workflow significantly influenced internal and marginal surface roughness of posterior tooth-colored crowns. The crowns survival rates were more closely associated with material type than fabrication method.

Introduction:
This in vitro study evaluated internal and marginal surface roughness and simulated thermocycling survival of posterior tooth-colored crowns fabricated using conventional laboratory, CAD/CAM milling, and digital light processing 3D printing workflows.

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