Dental Materials Journal 2011; 30(3): 281285

The influence of zirconia coping designs on the fracture load of all-ceramic

molar crowns
Yuji KOKUBO1,2, Mitsuyoshi TSUMITA1, Takamitsu KANO1 and Shunji FUKUSHIMA1
Department of Fixed Prosthodontics, Tsurumi University School of Dental Medicine, 2-1-3 Tsurumi Tsurumi-ku, Yokohama 230-0063 Japan
Division of Oral and Maxillofacial Implantology, Tsurumi University School of Dental Medicine, 2-1-3 Tsurumi Tsurumi-ku, Yokohama 230-0063 Japan
Corresponding author, Yuji KOKUBO; E-mail: kokubo-y@tsurumi-u.ac.jp

1
2

This study investigated the influence of zirconia coping designs on the fracture load of all-ceramic crown. Four kinds of zirconia
copings were designed (a: Conventional zirconia coping with flat occlusal surface: thickness of the each coping is 0.6 mm evenly, and
at the cervical margin area, the coping is adjusted sharply so as to fit preparation margin, b: Conventional zirconia coping with
shoulder collar of 1 mm: thickness of the each coping is 0.6 mm evenly, and there is a collar of 0.6 mm from the margin, c: Zirconia
coping with following original cuspal configuration (concave): two inclined cusp planes, and at the cervical margin area, the coping is
adjusted sharply so as to fit preparation margin, and d: Zirconia coping with supporting configuration on the occlusal area: supporting
configuration against the occlusal force, and at the cervical margin area, the coping is adjusted sharply so as to fit preparation
margin) and porcelain was fired. Vertical and lateral load were conducted until fracture. Coping design affected the fracture load;
conventional uniform thickness coping design showed the lowest load (a), whereas cuspal configuration to perform even thickness of
porcelain showed the highest fracture load both load directions (c).
Keywords: Framework design, Coping design, Zirconia, All-ceramic crown, Fracture load

INTRODUCTION
The alumina- or zirconia-supported ceramic crown
instead of metal-supported ones has been widely used
because of their high esthetics, biocompatibility, and
chemical durability. At the beginning, glass or alumina
have used for restorations of anterior teeth. The clinicians
have been attempted for restoring molar teeth, however,
the fracture problems often occurred not only from
porcelain but also from the coping, which showed global
fracture, and needed to replace1,2). The introduction of
zirconia copings, which were fabricated by computeraided design/computer-aided manufacturing (CAD/
CAM) or CAM technologies, has been developed precisely
and shown their high mechanical strength, as a result,
reduced fracture problems.
Until now, clinical results have shown that
all-ceramic crowns fabricated by using zirconia coping
showed high success rate after long-term function, only
minor chipping was detected particularly for molar
region3). There may be some reasons to fail of veneered
porcelain; flexural strength4), bond strength between
coping and porcelain5), excessive load6), porosities and
surface conditions of the porcelain7), improper coping
design8), and thermal stress when firing porcelain9). In
clinical case, there might have sever contact under some
situations, if there are no coping support of veneered
porcelain, chipping problems will increase.
Also, there might be some factors that will influence
the fracture evolution of all-ceramic crowns. Rekow et
al.10) revealed that the height of axial wall increases,
loads to cause failure increase. Other reports mentioned
that fracture load will depend on coping thickness,
marginal design, and applied luting agent11-13). Mori14)
Received Aug 18, 2010: Accepted Dec 3, 2010
doi:10.4012/dmj.2010-130 JOI JST.JSTAGE/dmj/2010-130

showed from in vitro study that the design of the yittria

stabilized zirconia (Y-TZP) framework with a
support-type is important for all-ceramic restorations.
At the beginning of introduction of high strength
structural ceramic Y-TZP, the coping was generally
fabricated uniform thickness to the prepared tooth.
Then, porcelain was fired on the coping to be completed
as all-ceramic crown. However, when fabricating the
cusp, veneered porcelain has been tended to be thick,
depending on the prepared tooth configuration. As the
porcelain is inherently brittle material, in case of lateral
load was applied to the cusps, it will be easily fractured,
or chipping, because porcelain is weak material against
tensile load. The modified coping design, which might
fabricate porcelain thickness evenly, or support the
occlusal and lateral load as compressive load could avoid
porcelain fracture. Molin et al.15) reported that one
technical approach to improve the clinical behavior is a
strict anatomically oriented framework design that
reinforce the ceramic veneer. Rosentritt et al. 16) concluded
that the change in the design of the coping should be
effectively reduced the number of chipping. Marchack et
al.17) reported that zirconia coping should be designed as
adequate coping thickness, adequate even porcelain
thickness, and butt joints at the porcelain-to-coping
junctions. However, they do not have long-term clinical
results to conclude. Furthermore, Bonfante et al.8)
showed the effectiveness of core-design modification of
In-Ceram crown on the fracture load when applying
vertical load at the central fossa, whereas Lorenzoni et
al.18) reported that there are no effect of core-design
modification of Y-TZP coping crown applying cyclic
loading.
The purpose of this study is to investigate the

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influence of zirconia coping designs on the fracture load

of all-ceramic crown. The hypothesis is that the design of
zirconia coping would influence the fracture load of
molar all-ceramic crown.

MATERIALS AND METHODS

The right mandibular first molar was prepared on
autoplymerizing resin (Pattern resin, GC Corp., Tokyo,
Japan) as replacement by all-ceramic crown according to
the manufacturers recommendation, which included
that mesial and distal, buccal, and lingual height were
3.0 mm, 5.5 mm, and 4.0 mm, respectively. Rounded
shoulder was conducted with 1.5 mm uniform width, and
convergence angle was 6.5 degree evenly. Then, all sharp
line angles were rounded (Fig. 1). This master model was

copied using same resin and casted for abutment teeth

using cobalt based casting alloy (Wisil, Elephant Dental
B.V., Hoorn, Netherlands ).
On the casted model, all-ceramic model was
completed by wax, and silicone core was recorded. Then,
four kinds of models were fabricated by using
autoplymerizing resin (Pattern resin) as follows (Fig. 2);
(a) Conventional zirconia coping with flat occlusal
surface: thickness of the each coping is 0.6 mm evenly,
and at the cervical margin area, the coping is adjusted
sharply so as to fit preparation margin.
(b) Conventional zirconia coping with shoulder collar of 1
mm: thickness of the each coping is 0.6 mm evenly,
and there is a collar of 0.6 mm from the margin.
(c) Zirconia coping with following original cuspal
configuration (concave): two inclined cusp planes, and
at the cervical margin area, the coping is adjusted
sharply so as to fit preparation margin.
(d) Zirconia coping with supporting configuration on the
occlusal area: supporting configuration against the
occlusal force, and at the cervical margin area, the
coping is adjusted sharply so as to fit preparation
margin.
All copings were double scanned by Procera Forte
(Nobel Biocare, Zurich, Switzerland), then Nobel Procera
crown zirconia copings (Nobel Biocare) were fabricated
as shown in Fig. 2. Each coping was checked the marginal
fit by using light scope, and completed by porcelain
(Nobel Rondo zirconia, Nobel Biocare) in a commercial
laboratory (KS Dental Laboratory, Yokohama, Japan),
following firing schedule; body porcelain, start temp.:

Fig. 1

Plastic model of prepared tooth (mandibuar first

molar).

Fig. 2

Completed designed copings.

(a)Conventional zirconia coping with flat occlusal surface: thickness of the each coping is 0.6 mm, and at the
cervical margin area, the coping is adjusted sharply so as to fit preparation margin.
(b)Conventional zirconia coping with shoulder collar: thickness of the each coping is 0.6 mm, and there is a collar
of 0.6 mm from the margin.
(c)Zirconia coping with following original cuspal configuration (concave): two inclined cusp planes, and at the
cervical margin area, the coping is adjusted sharply so as to fit preparation margin.
(d)Zirconia coping with supporting configuration on the occlusal area: supporting configuration against the
occlusal force, and at the cervical margin area, the coping is adjusted sharply so as to fit preparation margin.

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Dent Mater J 2011; 30(3): 281285

Fig. 3

Schematic drawing of completed all-ceramic crown.

650C, drying time: 5 min, temp. rising speed: 45C/min,

vacuum start (+), sintering temp.: 910C, holding time: 1
min, cooling time: 5 min, Glaze, start temp.: 650C,
drying time: 5 min, temp rising speed: 45C/min, vacuum
start (), sintering temp.: 880C, holding time: 1 min,
cooling time: 0 min.
Configuration of final crown was adjusted by using
silicone core. Ten all-ceramic crowns were fabricated for
each model (Fig. 3).
Before cementing, casted model and inside of
completed all-ceramic crowns were blasted by 50 m
alumina particle for 20 seconds, and applied AZ primer
(Shofu Inc. Kyoto, Japan). After that, crowns were luted
onto model by adhesive resin cement (ResiCem, Shofu
Inc.). After mixing, the cement was poured inside the
crowns using auto-mixing, and delivered on the model.
Then excess cement was removed, and was hold at 1 kg
weight from the top of the crown for 5 minutes. During
this procedure, no irradiation was conducted. All
cemented specimens were immersed in distilled water
for 24 hours before loading.
Cemented specimens were mounted in the testing
jig of a mechanical testing machine (Auto Graph
AGS-5kND, Shimadzu, Kyoto, Japan). Each group was
subdivided into two groups with five specimens in each
group, which included vertical loading group and 45
degree loading group. For the former group, a loading
rod with a 2.0-mm radius tip was positioned at the top of
buccal cusp so as to be loaded to the axial direction of
abutment. For the later group, a loading rod was
positioned so as to be loaded to inclined buccal cusp
plane. A load was applied at a crosshead speed of 0.5
mm/min until fracture (Fig. 4).
The initial fracture load was recorded, and mean
fracture load was calculated (SPSS 15.0.J, SPSS,
Chicago, IL, USA). The mean values of each group were
statistically analyzed using one-way analysis of variance
(ANOVA) to identify the significant differences among
coping designs. If differences were found, Tukey HSD
analysis was used to evaluate significant differences. All

Fig. 4

Mechanical strength test.

A loading rod was positioned at the top of buccal
cusp of crown or inclined lingual cusp plane, and
loaded until fracture occurred.

analyses were conducted at a 95 % confidence level.

RESULTS
The mean fracture load is shown in Fig. 5 (a and b).
When applying vertical load, Type c showed the highest
value, and there was a significant differences between
type a and c. On the other hand, when applying lateral
load, Type c showed the highest value. Type c showed
significantly higher load compared to other groups.
In this study, all fractures were occurred from
loading point to the buccal margin and proximal area
(Fig. 6), and cohesive failure with the veneered porcelain
were seen, which meant that failure modes were not
different form coping design. There were no coping
fractures during testing.

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Dent Mater J 2011; 30(3): 281285

(a)

(b)

Fig. 5

Fig. 6

(a) Fracture load when applying vertical load.

(b) Fracture load when applying lateral load.

SEM image after vertical loading.

DISCUSSION
Recently, review report by Al-Amleh et al.19) showed that
chipping of the veneering porcelain is confirmed to be an
ongoing problem with zirconia all-ceramic-based
restorations. At the beginning of introduction of zirconia
restorations, uniform thickness coping was used. This
means that so called supported area for veneered
porcelain was not designed. The combination of this
design and thick porcelain might increase the chance of
chipping. To reduce this problem, zirconia coping design
was modified. One of the suggestion of coping design
modification that might reduce the chipping troubles are
shown some researchers2,8,13,17), changing tensile loads to
compressive loads on the occlusal porcelain were
important when designing the copings. From these
points of view, in this study, four kinds of models were
designed; a: uniform thickness of the coping with sharp
marginal area which has been conventionally used

(control), b: uniform thickness of the coping which has

been conventionally used, and marginal area of the
coping is strong enough compared to design a, and c: two
inclined cusp planes, which might change the tensile
loads to compressive loads (lateral load), and at the
cervical margin area is designed the same with design a,
and d: supporting configuration against the vertical load,
and at the cervical margin area is designed the same
with design a.
When vertical load was applied, if the loading point
was within the framework of occlusal area, fracture load
might be high. In this study, Type b had supporteddesign on marginal area like Marchack et al.17) reported.
Further modification of marginal design will be needed
such as the height of collar needed for molar crown. If the
height increase, the width of it will increase, this would
support higher occlusal load. This means that after
full-contour waxing was conducted, it should cut back at
the top of the contour. This would be easily applied for
molar legion, where there will be not much esthetic
concern from patients. Type c showed the highest
fracture load, however, there were no significant
differences between Type c and d. From this result, for
vertical load, modification of marginal or occlusal design
would improve the fracture load.
When applying lateral load, Type c also showed the
highest value. This may be from a reason that lateral
load to veneered porcelain more or less changed from
shear to compressive load against the coping surface.
Type c showed the highest fracture load, and coping
design that can obtain high fracture load of all-ceramic
crown may offer predictable restoration. Ideally, after
fabricating working model, first wax-up the complete
crown, making silicone core, and then cut back the
wax-up so as to make the space for the porcelain veneer.
As a result, the coping will be fabricated with special
design depending on abutment configuration and
contralateral jaw.
Also, load position is very important like this in vitro
study, the load tended to tip the crown off the porcelain
from supporting coping. Rekow et al.10) discussed in his

Dent Mater J 2011; 30(3): 281285

reports that load position played a significant role in
stress concentration. When the load was applied in the
area beyond the bulk of the coping, tensile stress will be
concentrated at the coping-porcelain interface. Clinician
should keep in mind that there are many factors to be
affected the results, such as loading point, loading
direction, porcelain used, the conditioning of opposing
tooth, cuspal inner incline, biting force, and contact area.
From SEM observation, when loading, maximum
stress will concentrate at the tip of zirconia coping.
Initial failure was occurred from loading point, and cone
cracking within the veneered porcelain (cohesive failure)
as described previous reports3,19). From the failure mode,
the interface between porcelain and zirconia coping was
strong, whereas porcelain should be strong to decrease
the porcelain chipping. Also, Kelly20) revealed that
failures took place at repeated stresses lower than
materials bulk strength, further studies will be needed
after cyclic loading which simulate mastication.
When firing veneering porcelain to zirconia coping,
cooling protocol are key factors to avoid stresses within
the porcelain4,21). In this study cooling time was for 5
minutes to minimize the stress within the porcelain.
Bonfante et al.8) showed the effect of modified coping
design on the fracture load. On the other hand, Lorenzoni
et al.18) reported that framework modification did not
improve the fatigue life of the crown. These coping
designs were similar to Type b in this study. The
differences of these two articles were loading condition,
and materials used. Further studies will be needed to
investigate the fracture load after cyclic loading, because
this static loading might not be always simulate clinical
condition.
The hypothesis was confirmed. In this study, copings
were designed to support porcelain against the vertical
and lateral load. This means that modifying marginal
and occlusal areas were important to be completed this
design. There are no long-term clinical studies for molar
zirconia coping crowns to determine the influence of
coping designs.

CONCLUSION
Within the limitation of in this model study, the following
conclusions may be drawn;
1. Coping design affected the fracture load of zirconia
all-ceramic crown.
2. Cuspal configuration to perform even thickness of
porcelain showed the highest fracture load.

2)

3)
4)

5)

6)
7)

8)
9)
10)

11)
12)
13)
14)
15)
16)

17)
18)

ACKNOWLEDGMENT
We would like to thank Nobel Biocare for providing the
zirconia copings.

19)

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21)

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