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RESEARCH AND EDUCATION

Accuracy of marginal fit and axial wall contour for lithium


disilicate crowns fabricated using three digital workflows
Ramtin Sadid-Zadeh, DDS, MS,a Anastasia Katsavochristou, DDS, MS,b Taylor Squires, BS,c and Michael Simon, BSd

Marginal adaptation is a key ABSTRACT


factor in the long-term success
Statement of problem. Comparative assessment of the effectiveness of computer-aided design and
of restorations produced using computer-aided manufacturing (CAD-CAM) technologies used to fabricate complete-coverage
computer-aided design and restorations is needed. A quantitative assessment requires precise documentation of the marginal
computer-aided manufacturing adaptation and external surface contour of fabricated restorations. Limited information is currently
(CAD-CAM) technologies.1-3 available regarding the effects of milling mode on marginal adaptation and reproduction of the
Although marginal adaptation external surface contour for CAD-CAMefabricated restorations.
is affected by both vertical Purpose. The purpose of this in vitro study was to evaluate the outcomes for 3 different
and horizontal discrepancies, digital workflows on the marginal gap and the external surface contour reproducibility of
horizontal discrepancies can CAD-CAMefabricated lithium disilicate complete-coverage restorations.
be adjusted chairside.4 Thus, Material and methods. Twelve Ivorine molars were prepared to receive lithium disilicate crowns. The
together with the resistance preparations were digitally recorded using 2 intraoral scanners (TRIOS 3; 3Shape A/S and Planmeca
form, the marginal gap remains PlanScan; E4D Technologies), and the restorations were designed using their associated design
a major determinant of the software with reference to the anatomy of an unprepared tooth. The designed restorations were then
longevity of CAD-CAM resto- manufactured from lithium disilicate blocks using a 3-axis milling machine. Twelve restorations were
rations.5 Although luting agents manufactured using the detailed mode (Planmeca PlanScan detailed mode [PPD-D]), and 12 using the
standard mode for the Planmeca system (Planmeca PlanScan standard mode [PPD-S]). Restorations
can compensate for discrep-
from the 3Shape system were fabricated using the detailed mode (TRIOS 3Shape detailed mode
ancies in the marginal gap and [T3S-D]). The restorations were secured on their associated preparation with an elastomeric
resistance form, degradation of material. The marginal gap of each restoration was then measured in the ImageJ software using
the luting agent occurs as a images captured by a stereo microscope at ×20 magnification. External surface reproducibility was
result of occlusal forces and may evaluated by measuring undercut at 4-line angles using a dental surveyor. Differences in the
lead to secondary caries or marginal gaps of restorations fabricated using the 3 different workflows were compared by
reduction in fracture resistance Brown-Forsythe robust ANOVA, followed by a post hoc test (a=.05). Chi-square analysis (a=.05) was
used to evaluate differences in the contours of the external surface of the restorations, resistance
of the crowns.6-14 Luting agents
form, and marginal integrity produced using the 3 workflows.
fatigue as a result of micro-
leakage, changes in the elastic Results. The mean marginal gap for restorations fabricated using the T3S-D workflow was 60 mm, a
modulus, and plastic deforma- distance significantly lower (P<.05) than that of PPD-D and PPD-S workflows, which yielded a
marginal gap of 95 mm for the detailed mode and 124 mm for the standard mode of milling.
tion over timedconditions that Restorations fabricated using PPD-D and PPD-S workflows produced a significantly more
occur under dynamic occlusal reproducible external surface contour than those fabricated using the T3S-D workflow.
forces.15-17
Conclusions. Restorations fabricated using the T3S-D workflow produced the smallest marginal
The American Dental As-
gap. However, reproducibility of the external surface contour for this workflow was the worst of the
sociation specification no. 8 three workflows analyzed. (J Prosthet Dent 2020;123:121-7)

a
Assistant Professor, Department of Restorative Dentistry, School of Dental Medicine, University at Buffalo, Buffalo, NY.
b
Clinical Assistant Professor, Department of Restorative Dentistry, School of Dental Medicine, University at Buffalo, Buffalo, NY.
c
Dental student, School of Dental Medicine, University at Buffalo, Buffalo, NY.
d
Dental student, School of Dental Medicine, University at Buffalo, Buffalo, NY.

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122 Volume 123 Issue 1

MATERIAL AND METHODS


Clinical Implications A pilot study was performed to estimate the sample size
The CAD-CAM technology offers dental needed to evaluate the marginal gap for CAD-CAM
practitioners the ability to produce an acceptable lithium disilicate crowns. Crowns were fabricated using
complete-coverage restoration. These results 2 different intraoral scanners and their associated design
confirm that the CAD-CAM technology may software and fabricated using standard and detailed
produce complete-coverage restorations with milling modes. Four workflows were evaluated. The first
clinically acceptable marginal gaps and external and second workflows used the Planmeca PlanScan in-
surface contour, depending on the selected traoral scanner and design software (E4D Technologies),
workflow. followed by manufacturing of the designed restoration in
the standard milling mode (Planmeca PlanScan standard
mode [PPD-S]) or detailed milling mode (Planmeca
suggests a film thickness of 25 mm to 40 mm for luting PlanScan detailed mode [PPD-D]). The third and fourth
agents.18 However, clinical evaluation of complete- workflows used the TRIOS 3 intraoral scanner and the
coverage restorations suggests that typical marginal 3Shape design software (3Shape A/S), followed by
gaps, considered clinically acceptable for conventionally manufacturing of the designed restoration in the stan-
cemented restorations, range between 120 mm and 150 dard milling mode (TRIOS 3Shape standard mode [T3S-
mm.5,19 Moreover, the marginal gaps of CAD-CAM crowns S]) or detailed milling mode (TRIOS 3Shape detailed
produced by multiple CAD-CAM systems are reported to mode [T3S-D]). The specimens were prepared and
be between 58 mm and 200 mm, suggesting that this range evaluated as described in the following paragraphs for
encompasses acceptable values.20-27 Although marginal the large-scale study. Results from the pilot study re-
gaps between 25 mm and 40 mm are rarely achieved, these vealed that complete-coverage restorations fabricated
small marginal gaps should be considered the goal.28 using the T3S-S workflow required significant internal
The effects of different technologies on the accuracy of adjustment to be seated on their preparations. They had
external surface reproductions based on preparation scans a mean marginal gap of 188 mm, a value considered
are considered in the establishment of embrasure and unacceptable. As a result, the T3S-S workflow was
contact points with neighboring teeth, thereby impacting eliminated from the large-scale study.
the cleanability of interproximal surfaces. Moreover, A power analysis was performed for the remaining 3
reproduction of the external surface affects CAD-CAM workflows using the G*Power software. The total sample
retrofitted crowns for existing removable partial dentures size was calculated based on an effect size(f) of 0.8, an
(RPDs). The successful use of the CAD-CAM technology alpha error probability of 0.05, and a power of 0.9. The
has been reported in the chairside production of survey results of the power analysis revealed that a minimum of
crowns fitted to the existing RPDs.29-32 However, similar to 8 specimens per workflow were needed to perform the
laboratory CAD-CAM systems,33 a more critical evalua- study. However, to increase the power, the study was
tion of chairside technologies is needed in the context of performed using 12 specimens per workflow.
reproduction of existing survey crowns. Twelve Ivorine molar teeth (Kilgore International, Inc)
Multiple factors may influence the accuracy of CAD- were prepared by 1 operator (R.S.-Z.) with a 2-mm
CAM complete-coverage restorations. These include the occlusal reduction with reference to the occlusal anat-
quality of tooth preparation,34 optical scanner,35-40 omy of the tooth and a 1-mm modified shoulder fin-
design software settings, manufacturing process (mode ishline width. The preparations were then smoothed with
of milling, number of axes in the milling machine, and a finishing bur, and the line angles were rounded. Each
diameter of rotary instruments used to cut the internal preparation was digitally recorded using 2 intraoral
and external surfaces of the restoration), and type of scanners (TRIOS 3; 3Shape A/S and Planmeca PlanScan;
material used to fabricate the restoration. The purpose of E4D Technologies). Scanning was performed while the
this study was to evaluate the marginal gaps and accu- preparations were mounted on a typodont (200 Series;
racy of the external surface contours of lithium disilicate Kilgore International, Inc). The unprepared tooth used
crowns fabricated by using 3 digital workflows and 2 for the surveying procedure was scanned along with each
different modes of milling. The authors are unaware of preparation to represent the before-preparation scan. A
previous studies assessing the accuracy of lithium dis- standardized scanning procedure was used for all
ilicate crowns using various modes of milling. The null specimens.
hypothesis was that no difference would be found in the Restorations were designed with reference to the
marginal gap and reproduction of the external surface scans of unprepared teeth. The “Pre-op” design was
contour of complete-coverage restorations fabricated selected from the tooth library and applied to the prep-
using the 3 digital workflows. aration at the design tab for designing PPD-S and

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January 2020 123

Figure 1. Internal parameters for designed restoration in Planmeca system. A, Spacer thickness. B, Margin ramp.

PPD-D crowns. No modification was applied to the


external design of the restoration. Only minor smoothing
at the margin was applied using the “Smooth Surface”
tool. Based on common practice in fixed prosthodontics,
a cement spacer (defined as “Spacer Thickness” in the
software) of 50 mm was input for the occlusal and axial
walls of the preparation, and a finishline width (defined
as “Margin Ramp” in the software) of 0.8 mm was
selected (Fig. 1).
To design crowns in the T3S-D workflow, the anat-
omy of the unprepared tooth was morphed into the
restoration design so that the definitive design followed
the anatomy of the unprepared tooth. A cement spacer
(defined as “Extra Cement Gap” in the software) of 50
mm and a finishline width (defined as “Distance to Figure 2. Internal parameter for designed restoration in 3Shape system.
Margin Line”) of 0.8 mm were selected. In the design
software used for the T3S-D workflow, the cement gap preparations. Overcontoured margins were modified
was set to 25 mm, and the smooth distance was set to 0.2 after assessing the restorations on their preparations. No
mm. Figure 2 shows the definition for each set of values. modifications were made on the intaglio surfaces of the
Designed restorations were fabricated from lithium restorations. The restorations were then crystallized using
disilicate (IPS e.max CAD; Ivoclar Vivadent AG) using a a processing oven (Programat CS2; Ivoclar Vivadent AG)
3-axis milling machine (PlanMill 40; E4D Technologies). according to the manufacturer’s instructions.
A sprue was set in the mid-buccal location before For evaluation, the marginal gap was defined as the
sending the design to the milling machine. Designed perpendicular measurement from the internal surface of
crowns in PPD-S and PPD-D workflows were sent to the the crown to the part of the preparation closest to the
milling machine for manufacturing in 2 milling modes, finishline.4 Restorations were secured on their prepara-
standard and detailed. Designed crowns in the T3S-D tions with an elastomeric material (Fit Checker Blue; GC
workflow were sent to the milling machine using the America), and finger pressure was applied for 1 min-
Job Supplier Software (E4D Technologies) for ute.4,41 They were then placed under a constant load of
manufacturing in the detailed milling mode. The PlanMill 1.96 N for 1 minute at room temperature. A stereo-
40 uses a tapered rotary instrument (Two Striper; Pre- optical microscope (SMZ-U; Nikon Instruments, Inc)
mier) to mill the external surface of the restorations and 2 was used to capture images (×20) of the buccal, lingual,
rotary instruments to mill the intaglio surfaces, depend- mesial, and distal sides of each preparation and crown.
ing on the milling mode (ellipsoidal rotary instrument for To standardize the imaging, 4 devices were fabricated for
the standard mode and conical rotary instrument for the the buccal, lingual, mesial, and distal sides of the un-
detailed mode). prepared tooth using polyvinyl siloxane (Lab Putty;
After the crowns had been milled, the sprues were Coltène). Two nails were attached to a metal ruler, and
removed, and the restorations were inserted into their the ruler was indexed in the putty. Three locations were

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124 Volume 123 Issue 1

Table 1. Definitions for clinically evaluated parameters


Resistance Clinically acceptable: no rotation around x or y axis
form Not clinically acceptable: rotation around x and/or y axes
Marginal Explorer moves smoothly during occlusogingival movement
integrity at margin
Explorer catches during occlusogingival movement in limited
location, but marginal integrity clinically acceptable
Marginal integrity not clinically acceptable
Ranking of Rank restorations for each preparation from 1 to 3, with 1
restorations being the best choice.
1. ______2. ______ 3. ______

Figure 4. Device fabricated for 0.5-mm undercut at distobuccal location


of unprepared tooth.

each preparation were placed in 3 identical small boxes.


Boxes were placed in a bag and mixed. Restorations
were then randomly picked up from the bag by 1 of the
authors (M.S.), and they were assigned to a letter of A, B,
or C in order. After the randomization process, a blinded
and experienced clinician (R.S.-Z.) evaluated the resis-
tance form and marginal integrity using ×3 magnification
and an explorer based on the rubric presented in Table 1.
The clinician also scored the restorations from 1 to 3,
with 1 representing the best clinical outcome and 3
representing the worst.
The external surface contour of each crown was
evaluated by assessing the undercuts at the mesiobuccal,
distobuccal, mesiolingual, and distolingual line angles.
Figure 3. A, Image captured by optical microscope. B, Vertical line drawn
to margin. C, Measurement made at margin.
Four dental surveyor cast holders (Ney Lab Surveyor;
Dentsply Sirona) were used to locate undercuts on the
line angles of an unprepared tooth. Four typodonts (200
marked on the ruler to ensure that the marginal gap was Series; Kilgore International, Inc) were used to tilt the
measured at the same point of each mark for all speci- cast holders to locate 0.25-mm undercuts on the
mens. One operator (M.S.) measured marginal gaps. An mesiobuccal and distobuccal line angles and 0.5-mm
imaging software program (ImageJ; the National In- undercuts on the mesiolingual and distolingual line an-
stitutes of Health) was used to measure the marginal gap gles using the dental surveyor undercut gauges. An
of each restoration at 3 points per side, yielding a total of autopolymerizing resin (Pattern Resin LS; GC America)
12 data points per restoration. Using tools in the imaging was used to secure the location of each undercut using
software, a vertical line was drawn from the defined point gauges placed at each line angle (Fig. 4).
to the margin of the restoration, and the marginal gap The restorations were secured on their associated
was measured (Fig. 3). Then, fabricated restorations for preparations using an elastomeric material (XLV Virtual

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January 2020 125

Table 2. Marginal gap (mean ±standard deviation) measured for Table 3. Contingency table for marginal integrity and resistance form of
complete-coverage restorations in each digital workflow restorations in each workflow
Mean ±SD (mm) Variable PPD-S PPD-D T3S-D
Tooth Surface PPD-S PPD-D T3S-D Marginal integrity
Mesial 99 ±79 72.2 ±61 61.3 ±38 Clinically acceptable 3 10 12
Distal 122.5 ±89 81.4 ±63 52.7 ±35 Not clinically acceptable 9 2 0
Buccal 148.4 ±82 132.4 ±72 57.6 ±29 Resistance form
Lingual 124.9 ±66 93.6 ±51 63.3 ±28 Clinically acceptable 0 5 12
Total 123.7 ±81a 94.9 ±66b 59.7 ±33c Not clinically acceptable 12 7 0

PPD-D, Planmeca PlanScan detailed mode; PPD-S, Planmeca PlanScan standard mode; PPD-D, Planmeca PlanScan detailed mode; PPD-S, Planmeca PlanScan standard mode;
SD, standard deviation; T3S-D, TRIOS 3Shape detailed mode. Means labeled (total) with T3S-D, TRIOS 3Shape detailed mode.
different superscript letters are significantly different (P<.05).

Acceptable Restoration (%)


XD; Ivoclar Vivadent AG). Then, the cast holders and their 120 Marginal integrity Resistance form
associated typodont were used to evaluate undercuts on 100
the defined line angles for the unprepared tooth and the 80
preparation-crown assembly. The undercuts on the
60
preparation-crown assembly were compared with those
40
on the unprepared tooth. The visual result was reported as
“yes” when the undercuts were identical to the unpre- 20
pared tooth and “no” when they were not. 0
Statistical analyses were performed using a statistical PPD-S PPD-D T3S-D
Digital Workflow for Fabrication of Restorations
software program (IBM SPSS Statistics, v19; IBM Corp).
Brown-Forsythe robust ANOVA followed by the Games- Figure 5. Clinically acceptable restorations (%) with marginal integrity
Howell multiple comparison post hoc test was used to and resistance form after clinical evaluation for each digital workflow.
compare differences in the mean marginal gap between PPD-D, Planmeca PlanScan detailed mode; PPD-S, Planmeca PlanScan
the 3 digital workflows (a=.05). Chi-square tests evalu- standard mode; T3S-D, TRIOS 3Shape detailed mode.

ated the effects of different digital workflows on the


resistance form and marginal integrity (a=.05). Descrip-
“clinically acceptable” category, and class 3 was consid-
tive statistics were calculated to analyze the reproduction
ered “not clinically acceptable.” Then, chi-square analysis
of undercuts. The best-ranked workflow for each prep-
was used to evaluate the effect of the digital workflow on
aration was reported descriptively.
marginal integrity. The results showed no significant
differences (P>.05) in clinical evaluation of the marginal
RESULTS
integrity of restorations fabricated using the T3S-D and
The mean and standard deviation of the marginal gap for PPD-D workflows. However, the marginal integrity of
each digital workflow are presented in Table 2. The equal PPD-S restorations was significantly (P<.05) worse than
variance assumption was not met (P<.001), so the that of the other workflows. The chi-square analysis also
Brown-Forsythe robust ANOVA followed by the Games- showed that restorations fabricated using the T3S-D
Howell multiple comparison post hoc test was used to workflow had a significantly better (P<.05) resistance
compare the mean marginal gaps of the 3 digital work- form than those fabricated using the PPD-D workflow
flows. The robust ANOVA revealed a significant differ- (Fig. 5). Similarly, restorations fabricated using the
ence (P<.05) between the workflows. The Games-Howell PPD-D workflow had significantly better (P<.05) resis-
multiple comparisons showed that the marginal gap for tance form than those fabricated using the PPD-S
the T3S-D workflow was significantly smaller (P<.05) workflow. When the blinded clinician ranked the resto-
than that for the PPD-S and PPD-D workflows. In rations, lithium disilicate crowns fabricated using the
addition, the PPD-D workflow yielded a significantly T3S-D workflow were always selected as the first choice,
smaller marginal gap (P<.05) than the PPD-S workflow. and the restorations fabricated using the PPD-D work-
Table 3 shows the number of crowns with “clinically flow were ranked as the second choice 92% of the time.
acceptable” and “clinically not acceptable” marginal When chi-square analysis was used to evaluate the
integrity and resistance form in each workflow. When impact of digital workflows on the reproduction of un-
chi-square analysis was used to compare the marginal dercuts, the assumption of large expected frequencies
integrity of the restorations based on the 1, 2, and 3 was not met, so the results were reported descriptively.
rankings (Table 1), the assumption of large expected Undercuts were reproduced in 71% of the predetermined
frequencies was not met. As a result, the 1 and 2 rankings locations for the PPD-S workflow, 81% for the PPD-D
for marginal integrity were combined into a single workflow, and 40% for the T3S-D workflow (Fig. 6).

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126 Volume 123 Issue 1

milling resulted in a better vertical marginal fit (60 mm)


Reproduction of Undercuts (%)
90
80 than fabrication of crowns using conventional techniques
70 (74 mm). A similar marginal gap for crowns produced
60 using the T3S-D workflow was reported in this study (60
50 mm), although the die material, intraoral scanner, design
40
software, and milling unit differed from those of the
30
previous study. The marginal gap values reported here
were also similar to those reported by Alqahtani26 (60
20
mm) and Yang et al27 (58 mm). Similar to this study, in the
10
studies by Alqahtani and Xang et al,26,27 a TRIOS
0
PPD-S PPD-D T3S-D intraoral scanner was used to record the preparation, and
Digital Workflow for Fabrication of Restorations the 3Shape design software was used to design the
Figure 6. Percentage of undercuts reproduced for each digital workflow. associated restoration. However, these studies did not
PPD-D, Planmeca PlanScan detailed mode; PPD-S, Planmeca PlanScan report the settings for the design software, and a 5-axis
standard mode; T3S-D, TRIOS 3Shape detailed mode. milling machine was used to mill the restorations.26,27
The mean marginal gap was 123.7 mm for the PPD-S
workflow and 94.9 mm for the PPD-D workflow. In
DISCUSSION
contrast, Neves et al23 reported that the marginal gap for
The null hypothesis that the digital workflow does not crowns fabricated using the Planmeca system was 66.9 mm.
impact the marginal gap and reproduction of the external The different values may be due to a difference in the se-
surface contour of restorations was rejected. In this study, lection of the die spacer, which was 100 mm for the study by
an elastomeric material was used to secure the restorations Neves et al.23 Unfortunately, the study did not specify the
on their associated prepared teeth because of its low film marginal ramp setting and milling mode used for the
thickness.5 Similar to the replica technique, this method experiment, making direct comparisons difficult. In addi-
allows for evaluation of the marginal fit of restorations tion, the mean marginal gap for the PPD-S workflow was
fabricated using different workflows on a single prepara- higher than that reported by Renne et al34 using the same
tion. An advantage of this technique over the replica workflow (123.7 mm versus 62.3 mm). This discrepancy may
technique is that in the replica technique, the vertical cut at be due to the selection of a much smaller marginal ramp
the margin and the location of the cut cannot be precisely value and the use of a much thicker die spacer in their study.
determined for all specimens, leading to potential vari- These selections may compensate for the lack of smooth-
ability in measurement of the marginal gap. In contrast, ness associated with a 1-mm finishline width, resulting in a
measurement of the marginal gap through a combination better marginal fit. However, changes in the setting may
of microscopy and the putty-ruler assembly provided ac- also modify the resistance form of the restoration, which
curacy in vertical measurement at the margin and repro- was not evaluated in the study by Renne et al.34 The present
ducibility of measurement locations. One limitation of this study evaluated the resistance form of the restorations
technique is that as in the replica technique, the marginal defined as rotation around the x or y axis. The results of
gap is only measured at preset points, potentially missing clinical evaluation showed that the resistant form of the
marginal discrepancies in other locations. Moreover, in restorations fabricated using the T3S-D workflow was
this technique, internal adaptation of the restorations significantly better than that of the other workflows
cannot be evaluated. However, the marginal integrity of (P<.05). This factor contributed strongly to the selection of
the crowns was also evaluated clinically across 360 degrees crowns fabricated using the T3S-D workflow as the best
of the crown margin by an experienced evaluator; as a choice. In contrast, the differences between marginal gap
result, any undetected unacceptable marginal gaps not data reported by different studies might be inevitable. For
recorded by digital photography should have been noted example, Renne et al24,34 reported an average marginal gap
in the clinical evaluation. of 81 mm, a higher marginal gap than that reported in their
The marginal gap of crowns fabricated using the previous study, although the protocol remained the same.
T3S-D workflow was significantly (P<.05) smaller than The authors are unaware of a study that has evaluated
that of the other workflows. Differences between the the external surface contour of an existing surveyed crown
PPD and T3S workflows could result from the quality of using an intraoral scanner. Workflows used in this study
images captured during the scanning process.37,38 Images did not reproduce 100% of the undercuts. However, the
captured by the intraoral scanner used in the PPD PPD-S and PPD-D workflows reproduced the pre-
workflow have been shown to have an unclear transition determined undercuts better than the T3S-D workflow.
area between the triangles with a high level of noise.38-40 These data differ from those of CAD-CAM crowns eval-
A recent study25 found that fully digital fabrication of uated using a laboratory scanner, which exhibited signif-
a lithium disilicate crown by intraoral scanning and icantly smaller gaps in all of the clasp regions and

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January 2020 127

significantly higher retentive forces for RPDs compared 19. Fransson B, Oilo G, Gjeitanger R. The fit of metal-ceramic crowns, a clinical
study. Dent Mater 1985;1:197-9.
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the data gathered from the present study do not support Acta Odontol Scand 1993;51:129-34.
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