Fatigue Strength and Microstructural Evaluation of Zirconia Implant Specimens Fabricated Using a Large-area Additive Manufacturing System
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Purpose: This study evaluated the mechanical stability of zirconia specimens fabricated using a large-area additive manufacturing (AM) system, with a focus on their clinical applicability as dental implant materials. Materials and Methods: Zirconia specimens were manufactured using a digital light processing (DLP)-based vat photopolymerization system equipped with a large build platform (685 mm × 350mm × 20 mm). The material used was 3 mol% yttria-stabilized tetragonal zirconia polycrystal (3Y-TZP). Surface morphology was assessed using scanning electron microscopy (SEM). Fatigue strength was evaluated in accordance with the International Organization for Standardization (ISO) 13356:2015 under cyclic loading between 32 and 320 MPa at a frequency of 12 Hz for 1,000,000 cycles (R-ratio = 0.1). Tests were conducted at room temperature with specimens immersed in normal saline. Results: SEM analysis revealed no surface defects or cracks. High-magnification images showed densely packed zirconia grains, most of which were smaller than 600 nm. All specimens (n = 5) withstood fatigue testing without any signs of fracture or cracking under the applied conditions. Conclusion: Zirconia specimens fabricated using the large-area AM system satisfied the ISO 13356:2015 mechanical requirements, particularly fatigue resistance. These findings demonstrate that the system can produce zirconia dental implant components with adequate structural stability, supporting its clinical applicability and potential for high-throughput production.
Abstract
Purpose: This study evaluated the mechanical stability of zirconia specimens fabricated using a large-area additive manufacturing (AM) system, with a focus on their clinical applicability as dental implant materials. Materials and Methods: Zirconia specimens were manufactured using a digital light processing (DLP)-based vat photopolymerization system equipped with a large build platform (685 mm × 350mm × 20 mm). The material used was 3 mol% yttria-stabilized tetragonal zirconia polycrystal (3Y-TZP). Surface morphology was assessed using scanning electron microscopy (SEM). Fatigue strength was evaluated in accordance with the International Organization for Standardization (ISO) 13356:2015 under cyclic loading between 32 and 320 MPa at a frequency of 12 Hz for 1,000,000 cycles (R-ratio = 0.1). Tests were conducted at room temperature with specimens immersed in normal saline. Results: SEM analysis revealed no surface defects or cracks. High-magnification images showed densely packed zirconia grains, most of which were smaller than 600 nm. All specimens (n = 5) withstood fatigue testing without any signs of fracture or cracking under the applied conditions. Conclusion: Zirconia specimens fabricated using the large-area AM system satisfied the ISO 13356:2015 mechanical requirements, particularly fatigue resistance. These findings demonstrate that the system can produce zirconia dental implant components with adequate structural stability, supporting its clinical applicability and potential for high-throughput production.