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Review

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Ceramics as biomaterials for


dental restoration
Expert Rev. Med. Devices 5(6), 729–745 (2008)

Wolfram Höland†, Sintered ceramics and glass–ceramics are widely used as biomaterials for dental restoration,
Marcel Schweiger, especially as dental inlays, onlays, veneers, crowns or bridges. Biomaterials were developed
Ronny Watzke, either to veneer metal frameworks or to produce metal-free dental restorations. Different types
of glass–ceramics and ceramics are available and necessary today to fulfill customers’ needs
Arnd Peschke and
(patients, dentists and dental technicians) regarding the properties of the biomaterials and the
Heinrich Kappert processing of the products. All of these different types of biomaterials already cover the entire

Author for correspondence
range of indications of dental restorations. Today, patients are increasingly interested in metal-
Research and Development,
free restoration. Glass–ceramics are particularly suitable for fabricating inlays, crowns and small
Ivoclar Vivadent AG,
bridges, as these materials achieve very strong, esthetic results. High-strength ceramics are
Bendererstr. 2, FL-9494 Schaan,
Liechtenstein preferred in situations where the material is exposed to high masticatory forces.
Tel.: +423 235 3373
Fax: +423 239 4373 Keywords : biomaterials • ceramics • clinical applications • dental restoration • glass–ceramics • metal-free
materials • optical properties • strength • toughness
wolfram.hoeland@
ivoclarvivadent.com
Many review articles on the development and thoroughly tested for this purpose. A ceramic
application of ceramics in restorative dentistry coating or veneer was sintered onto the metal
mention the fact that the first feldspathic substructure to achieve an esthetic, tooth-like
enamel melts with quartz were produced appearance [9] . These PFM restorations con-
for fabricating restorative dental ceramics tinue to be popular today. Therefore, the first
for human medicine as early as in the 18th section of this publication is devoted to the
Century [1,2] . Dental crowns for anterior materials involved in the fabrication of these
teeth, or jacket crowns, were produced with restorations and the latest developments in
these feldspar materials [3,4] . Nevertheless, this veneering ceramics.
ceramic was highly susceptible to fracture and The second section deals with the metal-free
so never became widely used. In the 1960s, restorative solutions available today. The two
porcelain-fused-to-metal (PFM) systems were main groups, that is, sintered ceramics and glass–
developed, which were highly successful and ceramics, are discussed. Both types of materials
became very popular [5,6] . Since the mid-1980s, are presented together with their most important
restorative dental bio­m aterials have gained characteristics and applications. The fact that
popularity among patients as a result of the these two types of ceramics can be joined and
successful development and use of metal-free connected will also be addressed.
products for fixed dental restorations [7,8] . First, however, it is important to point out that
There are many reasons why people need dental the success of new biomaterials is measured by
inlays, crowns, veneers or bridges fabricated with their clinical performance. The level of the clini-
these restorative biomaterials. The cause may be cal success determines the degree of attractive-
of a medical (decay or periodontal reasons) or ness of the biomaterial for the patient. Therefore,
traumatic nature (accident). Other patients sim- the aim of any new development is clearly evi-
ply wish to change their smile to improve their dent. Modern ceramic systems are very reliable,
appearance. However, the demand for esthetic, esthetic materials but still show some restrictions
tooth-colored (‘invisible’) restorations increased in their spectrum of indications and there are
rapidly. No-one wants to cover up their mouth special clinical situations where they cannot be
when they smile. Until the mid 1980s, the stand- used. Future developments will aim to eliminate
ard biomaterial for restorative dental applications these limitations and clinical research has to be
was a ceramic supported by a metal framework. focused on the approval of new indications with
Biocompatible metal alloys were developed and an adequate level of evidence.

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Review Höland, Schweiger, Watzke, Peschke & Kappert

Before addressing the different types of materials and their spe- ceramics and sanitary porcelains. The main crystal phases,
cial characteristics (Table 1) and favorable processing properties, which should be mentioned in this context, include potassium
the most important prerequisites for dental restorations should be feldspar, KAlSi3O8 (K 2O·Al 2O3 ·6SiO2 ) and leucite, KAlSi 2O6
discussed. Restorative dental materials must meet the following (K 2O·Al 2O3 ·4SiO2 ) [17] . Owing to this background, dental
basic requirements: ceramics are often still called dental porcelains. The following
• They must be durable and biocompatible; composition range is typical for feldspathic veneering ceramics:
• Their optical characteristics (translucency and color in particular) 52–62 wt% SiO2, 11–16 Al2O3, 9–11 K 2O, 5–7 Na 2O with vari-
must be comparable to those of natural teeth; ous additional components, such as Li2O or B2O3 [18] . Ceramics of
this kind, which usually contain leucite as the main crystal phase,
• Their mechanical properties (strength and toughness) must meet have been presented by a number of authors [9,19,20] . In these
the requirements of the indication range (the required strength ceramics, the crystal phase is not formed by controlled nucleation
of an inlay is lower than that of a dental bridge). and crystallization as is the case in glass–ceramics. Rather, phase
Their wear behavior must be similar to that of natural teeth. As formation takes place in a fast, disordered, almost uncontrolled
a result, restorative dental materials are fundamentally different crystallization process. These ceramics may contain glass–ceramics
from those required to make implants and bioactive ceramics for as additional components (see ‘Leucite-based ceramics’ section).
bone replacements [10,11] . The most important silicate ceramics and their material systems
Restorative dental materials can be divided into two different include VM13 (Vita Zahnfabrik GmbH, Germany) [21] , Super
groups: silicate glass–ceramics and high-performance ceramics. Porcelain EX-3 (Noritake, Japan) [22] , Ceramco III (Dentsply,
Another possibility is a classification into materials with glassy USA) [23] , DuceramKiss (Degudent, Germany) and Imagine
phases (glass–ceramics or glass–infiltrated ceramics) or materials Reflex (Wieland, Germany).
with nearly no glassy phase (sintered, polycrystalline materials, such
as zirconium oxide). Both types of materials are used for different Leucite-based ceramics
indication ranges [12] . For example, modern, high-performance In order to improve the properties of silicate ceramics and take
ceramics, such as aluminium and zirconium oxide, are used to advantage of the principle of controlled crystallization found in
fabricate dental posts and high-strength bridges for load-bearing glass–ceramics, glass–ceramic components were built into feld-
areas of the mouth [13,14] . Silicate and glass–ceramics, however, spathic ceramics. Several review articles have been published on
are used either to coat these high-strength ceramics to make them the development and production of glass–ceramics [24–26] . The main
appear more esthetic and lifelike [15,16] or alone for single-tooth mechanism involved in the development of glass–ceramics is that of
restorations and small bridges. At present, therefore, a large vari- the controlled nucleation and crystallization of glasses. As a result,
ety of materials for the different fields of restorative dentistry are glass–ceramics contain at least one glass phase and one crystal phase.
available to dentists, dental technicians and, above all, patients. In Controlled surface crystallization and controlled bulk crystallization
this review, the most important biomaterials for restorative den- represent the two most important methods in this context.
tistry are separated into two groups: ceramics and glass–ceramics The IPS InLine® (Ivoclar Vivadent AG, Liechtenstein) was
for metal-reinforced restorations and ceramics and glass–ceramics developed on the basis of the knowledge gained in the produc-
for metal-free restorations. As well as providing a survey of each tion of feldspathic ceramics and glass–ceramics. IPS InLine
material category, the most recent and successful developments are contains both components that are used in the development of
presented. Therefore, both an overview of the materials and their glass–ceramics and also feldspar [27] . The material is classified as
indications and an outlook for the future will be offered. a dental ceramic. Nevertheless, the most important aspect of this
The greatest driving force to develop materials for dental restora- material is the glass–ceramic component, which forms the crystals
tion is to fulfill the patients’ needs. A great challenge was, and is, of the leucite type (KAlSi2O6) through controlled surface crystal-
the development of metal-free restorations with properties close lization. Controlled heat treatment alone in the temperature–time
to natural teeth (with respect to translucency, color or abrasive functions of these crystals causes crystals to form at the surface of
behavior) or even better mechanical properties and better durability the glass grains in granulated glass from the SiO2–Al2O3 –K 2O base
than natural tooth structures. system with additions of Na 2O, CaO, B2O3 and other oxides [28] .
The tetragonal modification of leucite crystals has a high linear
Metal-based restorations thermal coefficient of expansion [29] . As a result, the expansion
At present, ceramics and glass–ceramics for PFM restorations characteristics of the material can be adapted to those of the metal
still account for 50% of the market throughout the world. These substrate. Due to the formation of leucite crystals, the expansion
ceramics are used to veneer metal-based crowns and bridges. As a coefficient of the IPS InLine material is 12.6 ± 0.5 × 10 -6 K-1m/m
result, they still occupy a very important position in the market. after two firings at 910°C. After four thermal treatments, it
registers 13.2 ± 0.5 × 10 -6 K-1m/m.
Ceramics & glass–ceramics sintered on metal frameworks Metal–ceramic restorations involving biomaterials are fabricated
Most ceramics that are suitable for firing on dental alloys in several different steps, as well as including a number of materials
have been developed on the basis of the classical SiO2 –Al 2O3 – in the process: metals, an opaquer and different types of ceramics.
K 2O system, which is used primarily to produce household The individual ceramic materials are designed to fulfil the optical

730 Expert Rev. Med. Devices 5(6), (2008)


Ceramics as biomaterials for dental restoration Review

requirements of the different areas of the natural tooth. For exam- ceramic. It has the favorable characteristics of a good flexural
ple, a ceramic for simulating the appearance of the dentin portions strength of 80 MPa, good chemical durability (both according
(opaque, much chroma) of a tooth has different characteristics from to International Standards Organization [ISO] 6872) and an
those required in the translucent incisal region. adjusted thermal expansion of 12.0 ± 0.5 × 10 -6 K-1m/m. Due to
First, we would like to discuss the metals. The materials used the fluoroapatite crystals, the glass–ceramic possesses additional
in these applications include high-gold, palladium–silver and special optical features that are produced by a combination of
cobalt–chromium alloys, which show good biocompatibility [30] . different effects, including tooth color, translucency, brightness
Their expansion coefficient usually ranges between 13.8 × 10 -6 and opacity (which is also perceived as giving warmth to color).
K-1m/m and 16.2 × 10 -6 K-1m/m. After the metal framework has These optical properties provide the material with a tooth-like
been cast, the restoration is heat treated to form metal oxides on appearance. As a result, this glass–ceramic can be used to encase
the surface of the alloy. These oxides form the basis for the bond the metal frameworks of anterior restorations. However, it is also
with the ceramic layer, which is sintered to the metal as the first suitable for use in long-span bridges (Figure 1) .
inorganic component. This material is called an opaquer, as it
masks the metal. Furthermore, it establishes excellent prerequi- Ceramics & glass–ceramics pressed on metal
sites for applying the subsequent dental ceramics. The ceramics This review of metal-reinforced biomaterials would not be com-
from the composition range of 59.5–65.5 wt% SiO2, 13–18 Al2O3, plete if we did not mention the latest developments in this field:
10–14 K 2O, 4–8 Na 2O, which form the dentin and incisal parts silicate ceramics and glass–ceramics that are pressed onto metal
of the tooth are fired to the opaquer at a temperature of 930°C. alloys. Building on the fundamental knowledge of the chemical
In this process, the three types of materials are successfully fused and physical nature of glasses and glass–ceramics, and particu-
together. The IPS InLine ceramic is characterized by the pre- larly the favorable viscous flow properties of these materials at
viously mentioned thermal expansion and its flexural strength high temperatures [17,24,25,43] , researchers in the 1980s developed
of 80 ± 20 MPa, as well as its very good chemical durability. glass–ceramics using controlled nucleation and crystallization
Therefore, it fulfills the relevant dental standards [31,32] . methods [44] . The materials were transformed into a viscous state
The material is particularly suitable for veneering the metal and then pressed into the desired shape to produce dental resto-
frameworks of crowns and long-span posterior bridges. An exam- rations in dental laboratories. The first glass–ceramics that were
ple of one such clinical application is provided in the ‘Ceramics processed by taking advantage of the viscous flow principle are
and glass–ceramics PoM’ section, where the convenient technique discussed later.
of pressing ceramics onto dental metal alloys is presented. While these pioneering developments to harness the viscous
flow process were taking place, the idea to adapt this technique
Leucite–apatite glass–ceramics for veneering metal frameworks was born. Soon, a method was
As mentioned, research into the development of glass–ceramics has discovered that allowed these materials to be pressed onto cast
focused generally on the mechanisms of bulk crystallization and of metal substructures. The leucite ceramics from the following sys-
controlled surface crystallization for the formation of leucite crys- tems produce a successful bond when they are pressed onto metal
tals in particular. The combination of these methods was relatively frameworks: Authentic® (Ceramay), Ceramco® Press (Dentsply),
unknown [33–36] and had not been investigated in the development Super Porcelain EX-3 PRESS (Noritake).
of dental products. However, in order to
achieve both high expansion and strength
A B C
of the metal-reinforced ceramics and favor-
able optical properties, new possibilities had
to be explored. For this purpose, the surface
crystallization and the bulk crystallization
methods were combined [24,37,38] . As a result,
leucite crystals were precipitated by the mech-
anism of surface crystallization and needle-
like fluoroapatite crystals (Ca5[PO4]3F) were
formed through bulk crystallization in a glass
in the composition range of 49–58 wt%
SiO2, 11–21 Al2O3, 9–23 K 2O, 1–10 Na2O,
2–12  CaO, 0.5–6  P2O5 and 0.2–2  F.
Controlled nucleation always preceded
these crystallization processes [39–42] .
This glass–ceramic, used in a product Figure 1. Long-span, six-unit ceramic fused to metal bridge (IPS d.SIGN®), clinical
called IPS d.SIGN , is sintered to a frame-
® situation. (A) Preparation of the teeth. (B) The same bridge on the dental technician’s
work coated with an opaquer in a similar gypsum model before. (C) Cemented bridge.
Dentist: A Stiefenhofer; dental laboratory: Arteco.
way to the aforementioned IPS InLine

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Review Höland, Schweiger, Watzke, Peschke & Kappert

technique considerably speeds up work in commercial laboratories


through the possibility of full anatomical design and pressing. Even
A though some initial problems were encountered with this technique,
these have now been resolved. The coefficient of thermal expansion
(CTE) of compatible alloys has to be in the range of 13.8–14.5 × 10-6
K-1m/m. Today, the PoM technique can be used to fabricate dental
restorations ranging from crowns to multi-unit bridges (Figure 2) .
In the clinical case (Figure 2), the patient has lost three adjacent
teeth (24, 25, 26) of the left side of the upper jaw. This huge distance
poses a prosthetic challenge. It could be restored by means of den-
tal implants, a removable partial denture or a bridge (fixed partial
denture). However, owing to the missing bone structure no dental
implants could be inserted easily. A possible bone augmentation was
declined by the patient, and because of the high-quality rating of the
B canine tooth and the second molar, the author decided to restore the
distance of three teeth by means of a ceramic PoM bridge [45,46] . A
high-strength metal framework was used because of the good in vivo
and in vitro long-term survival results of long-span and multiple unit
bridges [47–60] . To save time in manufacturing the bridge, the dental
technician decided to press the ceramic to the framework altogether
instead of veneering it with different ceramic pastes step-by-step
(IPS d.SIGN presented in Figure 1). To achieve better esthetics in
the visible region a ceramic shoulder on the canine crown was used
to hide the metal framework (dark appearance cervical). The indi-
vidualization of the ceramic PoM bridge was performed by painting
the restoration. After try-in of the bridge and controlling esthetics
C
and function, it was cemented conventionally.
This case study shows the huge mechanical and esthetic poten-
tial of this material combination. This kind of fixed partial den-
ture is only possible using metal frameworks and they offer a very
beneficial and convenient therapy for the patient [61] .
Figure 2B clearly shows that the abutment crowns and the three pon-
tics are completely encased within ceramic. Since the dental ceramic
has a somewhat lower CTE than the opaquer, which in turn has a
lower coefficient than the metal alloy, the stresses within the material
are controlled, which strengthens the ceramic. This phenomenon
of controlling stresses has been addressed in various publications.
Nevertheless, the strength of the bond between the materials is the
most important factor in this context. Measuring methods and bond
Figure 2. Press-on-metal technique. (A) Clinical situation: strength parameters are prescribed for establishing the nature of the
preparation of teeth 23 and 27. (B) Long-span, five-unit (teeth
23–27) press-on-metal (PoM) bridge (IPS InLine® PoM) on mirror, bond, the most important being described in [62,63] .
23 with a ceramic shoulder for higher esthetics in the visible
region. (C) The same bridge in clinical situation after cementation Metal-free restorations
on to teeth 23 and 27. The development of metal-free dental restorations has always
Dentist: R Watzke; dental technician: A Ritter. been a focal issue of dental research and development efforts,
starting with the development of the jacket crown mentioned
The product category of ceramics that are suitable for pressing on earlier. In the meantime, additional research has been conducted
metal will be discussed on the basis of the IPS InLine press-on-metal into improving the strength of metal-free restoratives and achiev-
ceramic (Ivoclar Vivadent AG). The main advantage of the PoM ing tooth-like optical characteristics. The latest materials fulfil
technique compared with that of sintering glass–ceramics on an opa- these demands and, therefore, offer patients highly sophisticated,
quer is the fact that it allows dense materials to be fused together as a esthetic and reliable solutions (Table 2) . At the same time, the pro-
result of the virtually homogenous heat distribution and the viscous cessing techniques have been further developed to enhance the
flow process. This joining technique heightens the process reliability effectiveness of the products, save time and heighten reliability.
for the dental technician in the fabrication of dental restorations, As a result of these efforts, leucite-based ceramics were reinforced
and ultimately benefits the patient. At the same time, this pressing with crystalline Al2O3 [73,74] .

732 Expert Rev. Med. Devices 5(6), (2008)


Ceramics as biomaterials for dental restoration Review

Table 1. Summary of clinical advantages and risks for different restoration categories.
Advantages Disadvantages/risks
Metal–ceramic restorations
• High strength because of the metal framework [61] • Different materials fused together
• Frameworks with 5 or more units are possible (long span) [57] • Different CTEs
• Many studies have proved the clinical long-term • Susceptible to chipping or delamination of veneering
performance [47–60] material [48,59]
• Better esthetics in comparison with full-metal restorations [64] • Esthetics not as good compared with full-ceramic restorations
• Wear behavior similar to natural enamel [65–68] • Casting the framework is time consuming
• Possible repairing of chipped or delaminated veneering • Inhomogeneities within the metal framework because of the
material [69,70] casting process
• Good marginal fit [71,72] • Possible allergy towards metal ingredients
• Pressing the ceramic to the framework is time saving (e.g., IPS • Today, gold alloy used as the framework material is expensive
InLine® PoM) • Individualization just by means of painting the uniformly
• Individualization by means of different colored and translucent translucent ceramic
ceramic pastes (e.g., IPS d.SIGN®) • Veneering of the framework step-by-step is time consuming
Machinable leucite-type glass–ceramic restorations
• Only one appointment necessary • Expensive equipment
• No provisional restoration necessary • Additional extra oral work for the dentist
• No impression necessary • Limitations with regard to individualization/painting
• Time- and cost-saving procedure • Multiple units
• Longevity • Difficult to scan and design
• Esthetics • Teeth have to be powdered for intraoral scanning
• Preservation of tooth structure
• No dental technician/laboratory necessary
Full-ceramic restorations (high-strength and high-toughness sintered ceramics veneered with glass–ceramics)
• High strength because of the framework [198–201] • Different materials fused together
• Fewer inhomogeneities within the framework because of the • Different CTEs [212]
preformed ceramic milling blocks • Chipping or delamination of veneering material [213]
• Esthetically because of the veneering material • Fewer long-term studies than for ceramic fused-to-metal
• Biocompatibility [208] restorations (mostly short-term evaluations and case
• CAD/CAM framework saves manufacturing time for the reports) [202–206]
dental technicians • Short-time experience of durability of long-span
• Minimally invasive preparation of the tooth (inlay retained) [191–197] restorations [203–206]
• Wear behavior similar to natural teeth [68,209] • Individualization only by means of painting the uniformly
• Reparations of chipped or delaminated veneering material possible [210] translucent ceramic veneering of the framework step-by-step
• Good marginal fit [211] is very time consuming
• Pressing the ceramic to the framework is time saving (IPS e.max®
ZirCAD and ZirPress)
• Individualization by means of different colored and translucent
ceramic pastes (IPS e.max ZirCAD and Ceram®)
CAD: Computer-aided design; CAM: Computer-aided manufacture; CTE: Coefficient of thermal expansion; PoM: Pressed-on-metal.

Furthermore, composites involving ceramic and glass were pro- developments in glass–ceramics and polycrystalline ceramics
duced (VITA In-ceram® ALUMINA, SPINELL and ZIRCONIA; for restorative dental applications are described in the following
VITA Zahnfabrik). For this purpose, open-pored, sintered ceram- sections. Apart from the materials, engineering aspects and the
ics were infiltrated with glass. The strength of these specialized properties of the materials the processing techniques and various
composites was considerably higher than that of feldspathic ceram- clinical applications in particular should be discussed.
ics. At the same time, the optical properties were improved com-
pared with those of the opaque sintered ceramics. The presintered Moldable & machinable glass–ceramics for single units
ceramic framework contained predominantly alumina (Al2O3), The initial developments in the field of glass–ceramics were used
spinell (MgAl2O4) or zirconia (ZrO2 ; CeO2 stabilized type) as for technical purposes [81,82] . Today, a wide range of glass–ceram-
the crystalline phase. A low-viscosity glass containing La 2O3 was ics are available for use in the home, in technical and medical
used to infiltrate the open-pored ceramics [75–80] . fields, and of course in dentistry [24] . Early developments of glass–
At the same time as these developments were taking place, ceramic dental restoratives involved mica glass–ceramics [83–88] .
research into the glass–ceramic systems and the development This glass–ceramic was processed by means of centrifugal cast-
of high-strength polycrystalline ceramics was underway. The ing. Crowns and inlays were produced with this technique. The

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Review Höland, Schweiger, Watzke, Peschke & Kappert

translucency of the ceramic was controlled by precipitating disc- of this system provide almost ‘invisible’ restorations because the
shaped tetrasilicic mica. However, this process was overlapped translucency of the material is tuned to that of the tooth structure
by a surface reaction of the glass–ceramics with the investment and, therefore, allows a sort of ‘chameleon effect’.
material and the precipitation of enstatite-type crystals. After
removing this surface layer, the materials appeared more trans- Machinable materials
lucent. Apart from the centrifugal casting technique, machining Apart from being molded, the leucite glass–ceramic of the IPS
methods can be used to shape this material. Empress type (product name: IPS Empress CAD; previously
known as: IPS ProCAD) can be machined to produce inlays,
Molding technology onlays and crowns. Initially, the developers were surprised by
The development of the molding technique represented a signifi- the machinability of these leucite glass–ceramics using diamond
cant advance in the processing of dental ceramics. The technique milling tools and a special milling strategy. Up to that time, the
for molding leucite glass–ceramics to produce dental restora- machining properties of glass–ceramics were thought to be the
tions was developed by adapting the knowledge gained from result of the precipitation of mica crystals in the material [111,112] .
casting metals to the viscous flow principle [89,90] . The molding However, machinable ceramics that contained feldspar crystals
procedure is conducted at 1080°C in a special, automatically in the glass matrix (Vitablocs® Mark I and II [CEREC, VITA
controlled furnace. Leucite crystals are formed through a con- Zahnfabrik GmbH]) were also available since 1991. The extru-
trolled surface crystallization processes in the SiO2–Al2O3 –K 2O sion technique was used to integrate these crystals in the matrix,
materials system. This type of surface crystallization is related thereby causing internal stresses that made the material suitable
to the precipitation of crystals on each individual glass granule for machining [113] .
and, therefore, this surface crystallization mechanism is quite dif- Nevertheless, these glass–ceramics that contained crystals in
ferent from the enstatite formation on mica glass–ceramics [91] . the glass matrix were difficult to machine. Fortunately, a glass–
The precipitation of the crystals increases the strength of the ceramic featuring a composition similar to that of IPS Empress
glass–ceramic. Consequently, the IPS Empress® product exhibits was found to be suitable for milling purposes. The leucite crystals
flexural strength of 120–180 MPa in biaxial tests [1,92,93] . Apart in this glass–ceramic grow according to a certain process, which
from showing high strength, which renders the material suitable prevents the material from becoming too brittle. Therefore, this
for the fabrication of crowns, the glass–ceramic demonstrates a glass–ceramic shows optimum machining properties. In addition,
CTE of 15–18.5 × 10 -6 K-1m/m, very good chemical durability a multicolored computer aided design (CAD)/computer aided
and outstanding optical properties, which are similar to those of manufacturing (CAM) block was developed with this material.
natural teeth. Studies have shown that the biomaterial also pos- As a result, the color transitions and shading, as well as the dif-
sesses wear properties that are close to those of natural teeth [94] . ferent levels of translucency that are found in natural teeth, can
In a clinical study covering 11 years, a survival rate of 95.2% now be reproduced faithfully [114,115] .
was recorded for anterior crowns and 84.4% for posterior crowns The IPS Empress CAD glass–ceramic is milled with Cerec®
(based on Kaplan–Meier methodology) [95] . Studies on inlays equipment (Sirona, Germany) [116–119] . Before the restoration is
and onlays spanning 8 years showed a survival rate of 92% [96] . machined, a 3D image of the clinical situation is captured with
Equally high success rates were achieved in 6-year studies on an intraoral camera [120,121] . Since the 1980s, the technology for
inlays and onlays [97] . The largest study, involving more than 100 machining dental restorations has been improved systematically
clinical cases, showed a success rate of more than 90% [98] . In to produce highly accurate results. Improvements of the machin-
general, clinical success is closely linked to the use of a suitable ing technology from the beginning to today allows a precise fit
cementation technique. In this context, adhesive cementation onto the tooth with hardly any marginal gaps [118, 122–129] .
seems to be the most promising method [99] . Nevertheless, in Milling can be done either by the dental technician ‘lab-side’
comparisons between adhesive and conventional cementation or by the dentist ‘chair-side’. This method is a very interesting,
procedures, success rates of about 98% were achieved [100] . The fast and reliable alternative to labor-intensive conventional tech-
particularly esthetic properties of IPS Empress materials mean niques. The teeth can be restored in a single appointment and,
that they are recommended for the fabrication of anterior res- therefore, there is no need for provisional restorations. The clinical
torations [101,95] and any type of inlay, onlay or veneer (in the performance and longevity of this kind of CEREC restoration are
anterior or posterior region) [102–106] . well documented [130–146] and the esthetic results are convincing.
The IPS Empress glass–ceramics, in conjunction with the Owing to the reliability of adhesive luting techniques there is
dedicated furnace, have become firmly established in restorative no need for mechanical retention for these kinds of restorations;
dentistry for the fabrication of dental restorations, such as inlays, therefore, they offer an opportunity to preserve tooth structure.
onlays and crowns [15,107–109] . From 1991 to 2007, 33 million Figure 3 shows part of the procedure generating an IPS Empress
dental restorations were produced with this system (one unit CAD restoration machined with the CEREC 3D equipment. The
represents one inlay or one crown) [110] . A new system called molar showed an extensive defect, received a composite build-up
IPS Empress Esthetic, which offers improved optical properties and was prepared for an inlay restoration strictly according to the
and optimized microstructure compared with the classical IPS extension of the defect. The location was scanned with an intraoral
Empress system, was introduced in 2005. The optical properties scanner to generate a 3D model of the clinical situation. By means

734 Expert Rev. Med. Devices 5(6), (2008)


Ceramics as biomaterials for dental restoration Review

A B

C D

Figure 3. Generation of an IPS Empress computer aided design (CAD) restoration. (A) Large defect on an upper molar prepared
to receive an Empress CAD CEREC restoration. (B) Digital 3D model of the prepared tooth. (C) Design of the virtual inlay. (D) Empress
CAD Inlay adhesively luted and polished.
Dentist: A Peschke.

of the CEREC 3 CAD software, an anatomically correct inlay was with a product from the SiO2 –ZrO2 –P2O5 system containing
designed and milled out of a solid block. The inlay was adhesively Li12ZrSi6O15 crystals. The flexural strength of this glass–ceramic
luted using a composite cement and polished intraoraly. All steps was above 250  MPa; however, the material was very opaque.
were made in one appointment within approximately 2 h and the Subsequently, more translucent products were developed with
esthetic and functional results were very good. strengths of 120 MPa, which were suitable for pressing onto ZrO2
These kinds of restorations show survival rates of 89% after posts due to adjusted CTE of 9.5 × 10 -6 K-1 m/m [149,150] .
18  years [131], and thus are comparable to the results found Significantly higher strengths of 350 MPa were achieved with
with conventional ceramic inlays and cast gold inlay and onlay glass–ceramics of the SiO2–Li2O–K 2O–ZnO–P2O5–Al2O3–La2O3
restorations [147,148] . system by precipitating lithium disilicate (Li2Si2O5) crystals. The
IPS Empress 2 glass–ceramic is characterized by an interlocking
High-strength glass–ceramics for single units microstructure made up of disk-shaped, needle-like crystals. Its
& three‑unit bridges crystal content of up to 70% volume is considerably higher than that
Molding technology for single units & three-unit bridges of leucite materials [151–154] . The IPS Empress 2 type glass–ceramic
Once these glass–ceramics were being used successfully to fab- is moldable, as leucite glass–ceramics, but at a lower temperature of
ricate anterior restorations, a demand arose for similar materials 920°C. The linear CTE is 10.6 ± 0.5 × 10-6 K-1m/m.
that could be used to produce posterior restorations. For this Once the crown copings and bridge frameworks have been
purpose, the strength and toughness of these glass–ceramics had fabricated with the lithium disilicate glass–ceramic, they are
to be increased. Unfortunately, another materials system had to coated with an apatite glass–ceramic, which is subsequently sin-
be found, as leucite glass–ceramics cannot achieve strengths of tered. This improves the optical properties of the restoration and
more than 200 MPa. An initial increase in strength was attained enhances its tooth-like appearance.

www.expert-reviews.com 735
Review Höland, Schweiger, Watzke, Peschke & Kappert

of IPS e.max® Press, has a flexural strength of more than 440 MPa.
A Its fracture toughness, stated as the established fracture toughness
(K IC) value, was determined as 2.3–2.9 MPa·m1/2 [162,165,166] .
This lithium glass–ceramic can be pressed into different shapes
using the molding technique, hence the name IPS e.max Press.
As the microstructure of the lithium disilicate glass–ceramic end
product has a very high crystal content and the crystals are noncleav-
able, an induced fracture propagates around these crystals [165] . The
deflection of the crack is responsible for increasing the toughness
of the glass–ceramic.
The exceptional translucent properties of the lithium disilicate
glass–ceramic are achieved by adjusting the index of refraction of
the crystal phase to that of the glass matrix. This is important to
B note, as the crystal content is higher than 60% volume. As a result,
this material can be produced in different levels of translucency,
depending on the clinical requirements.
As with the IPS Empress 2, the IPS e.max glass–ceramic can
be coated with fluoroapatite glass–ceramic (IPS e.max Ceram) to
improve its optical properties and enhance its wear behavior [167] .
IPS e.max Ceram has a flexuaral strength of 90 ± 10 MPa, a good
chemical durability (both according to ISO 6872) and a CTE
of 9.5 × 10 -6 K-1 m/m, which matches the framework materials
lithium disilicate glass–ceramic and zirconium dioxide ceramic.
The fluoroapatite crystals allow the adjustment of translucency
and brightness in order to achieve a natural esthetic.
The results of clinical studies on the lithium disilicate glass–
ceramic IPS. e.max Press show that the framework of only one
Figure 4. IPS e.max® CAD LT restoration fabricated with restoration out of 121 crowns and 18 bridges placed adhesively and
computer aided design/computer aided manufacture using glass ionomer cement fractured in the first 23 months [168] .
technology (CEREC) in the chairside mode. (A) Try-in of a full
The results of 5-year studies revealed that a success rate of 96.7%
crown in its lithium metasilicate state. (B) The same crown after
final firing (shaded and glazed) and cemented. can be achieved if the specified dimensions, and those of the
Dentist: A Peschke. connectors of 4 × 4 mm 2 in particular, are observed [169] .

Clinical studies have shown that lithium disilicate glass– Machinable glass–ceramics for single units
ceramics of the IPS Empress 2 type are suitable for fabricat- The goal in the development of IPS e.max glass–ceramics was
ing crown copings and bridge frameworks. Nevertheless, as far to produce a material that could be molded (IPS e.max Press)
as bridges are concerned, the uses of this material should be or machined, thereby offering dentists and dental technicians a
restricted to fabricating three-unit bridges for the anterior region choice between two fabrication methods. This goal was achieved
up to the second premolars, as the chewing forces in this area by introducing an intermediate fabrication step. As the lithium
are lower than in the posterior region [155–157] . In addition, it is disilicate final product is very difficult to mill in chair-side mill-
very important to observe the design requirements of the bridge ing, units such as CEREC 3 (Sirona) and alternative options were
framework. For example, the dimensions of the connectors of explored. As a result, an intermediate product, a lithium metasili-
the individual bridge units must measure 4 × 4 mm 2 [158] . These cate glass–ceramic, was produced. This product called IPS e.max
specifications are important to observe, as the breaking load of CAD has a bluish color. The material is easy to machine in this
a lithium glass–ceramic bridge is between 1000 and 2000 N, intermediate stage but has poor chemical resistance. Therefore,
and therefore much lower than that of a high-strength sintered after it has been machined, the lithium metasilicate glass–ceramic
ceramic restoration [159] . is heat treated for a second time at 850°C. In this process, it is
The 3G™ OPC® product (Pentron Ceramic Inc., USA) is transformed into lithium disilicate glass–ceramic, which dem-
also composed of lithium disilicate glass–ceramic. It is derived onstrates tooth-like color, excellent chemical durability of under
from the SiO2–Li2O–BaO–CaO system. Its main characteristics 100 µg/cm2 (according to dental standard measurements) and
include high strength and molding processing [301] . high strength of 360 ± 60 MPa and toughness of 2 MPa·m1/2.
An improved lithium disilicate glass–ceramic was developed An example of this glass–ceramic, which initially has a blu-
in the SiO2 –Li 2O–K 2O–P2O5 –Al 2O3 –ZrO2 system. It showed ish tinge in its lithium metasilicate state, is shown in Figure 4 .
increased flexural strength and controlled translucency and Beside the facilitation of the milling process, it is also easier for
shade [160–164] . This glass–ceramic, which is sold under the name the dentist to accomplish occlusal or proximal adjustments of the

736 Expert Rev. Med. Devices 5(6), (2008)


Ceramics as biomaterials for dental restoration Review

restoration during try-in. After final adjustments it is possible to an induced crack transforms the ceramic from a tetragonal to a
individualize the restoration with shades and to glaze it before monocline modification (martensitic transformation), which is
terminal firing. This allows predicable functional and esthetic connected to an increase in volume; therefore, crack propaga-
results (Figure 4B) . tion is inhibited. Consequently, we could call this mechanism
These materials are rather new and, therefore, the clinical data stress-induced transformation strengthening.
are limited. However, preliminary results of prospective clinical
trials are promising, indicating low failure rates and good wear
behavior [170,171] . A

High-strength & high-toughness polycrystalline ceramics


veneered with glass–ceramics
Long before high-performance ceramics were used extensively in
the fabrication of dental crowns and bridges, ZrO2 was used to
create dental posts [150,152] . These ceramics were fused to glass–
ceramics using molding principles that intimately bonded the core
build-up with the post (Metal-based restorations).
In order to enable metal-free restorations to be used in all areas
of the mouth, even the posterior region, and for all types of resto-
rations, even bridges, high-performance ceramics featuring high
B
strength and high toughness had to be further developed and
adapted. First and foremost, suitable fabrication methods had
to be developed. Generally, a high-strength ceramic is used to
produce the framework, which is veneered with a silicate ceramic.
In the production of high-strength ceramics for the fabrication of
crown copings and bridge frameworks, Al2O3 and ZrO2 ceramics
are used predominantly. Machining is the preferred method for
fabricating dental restorations with these materials.
The previously mentioned CEREC milling system, which is
used to machine glass–ceramics, leucite ceramics and feldspathic
composites, is also suitable for cutting high-performance ceram-
ics in a presintered, open-pored state. In addition, a number
of milling systems have established themselves on the dental C
market for this purpose. The most important systems include
Procera® (Nobel Biocare, Göteborg, Sweden), Cercon® (Degussa
Dental, Hanau, Germany), LAVA™ (Espe Dental AG, Seefeld,
Germany), DCS® (DCS-Dental, Allschwil, Switzerland), Decim®
(Skelleftea, Sweden), Cicero® (Cicero Dental BV, Netherlands),
KaVOEverest® (KaVO EWL, Leutkirch, Germany), Ceramill®
(Amman Girrbach, Germany), ZirkonZahn® (Steger, Italy) and
Hint-ELs® (Hint-ELs, Germany).
Here we present an overview of the Al2O3 and ZrO2 materials
and a discussion of the special applications of ZrO2 ceramics.
Al2O3 ceramics in the form of Procera have been used to fabricate
crowns since 1991. Even bridges can be fabricated by sintering
together three different parts, which are fabricated from this mate-
rial (Procera alumina bridge). In addition, the Procera products Figure 5. Application of the veneering ceramic: molding/
include ZrO2 ceramics for the fabrication of bridges. The clinical pressing. (A) Teeth preparation (24 and 26) for a hybrid (crown
suitability of these products has been proven [172–174] . and inlay retained) full-ceramic three-unit bridge (IPS e.max®
A high-strength and high-toughness ceramic of the 3Y2O3 –ZrO2 ZirCAD and Zir Press), attend to the minimally invasive
type for the fabrication of dental restorations is available on the preparation of the premolar. (B) Hybrid full-ceramic bridge on
mirror, the high-strength IPS e.max ZirCAD ceramic is visible as
market. This material exhibits high flexural strength and tough- white framework, the margin is pressed with a glass–ceramic to
ness of 900–1200 MPa and a K IC value of 4–5 MPa·m1/2 (deter- achieve the best adhesion to tooth structure by means of luting
mined according to the single-edge V-notched beam [SEVNB] composite. (C) Adhesively luted hybrid full-ceramic bridge (IPS
method). The toughening mechanism of this ceramic has been e.max ZirCAD and Zir Press) in clinical situation.
thoroughly examined and discussed [175–179] . In this mechanism, Dentist: R Watzke; dental technician: F Perkon.

www.expert-reviews.com 737
Review Höland, Schweiger, Watzke, Peschke & Kappert

High-performance ceramics are predominantly machined


to produce dental restorations (finished product or presintered
A
open-pored product) or processed through sonoerosion [180]
or electrophoresis precipitation [302,303] . Milling is the most
frequently used processing technique. Two possibilities are
available: machining of the finished product or machining of
a presintered, open-pored ceramic. In the first case, high-per-
formance computer numerical control machines are required
(e.g., DCS and Decim). Nevertheless, as the ZrO2 ceramic is
very strong and tough it is very difficult to mill. Therefore,
processing systems have been designed to machine open-pored
intermediate products, which are subsequently sintered to pro- B
duce the finished product. As the volume of the work pieces
shrinks in the firing process, oversized restorations have to be
cut from the intermediate product, which take into account
this shrinkage. The LAVA and Cercon systems, for example,
use this technique.
The 3Y2O3 –ZrO2 ceramic of the LAVA system is reported to
show strength values of approximately 930 MPa (three-point
bending) and a K IC value of 5 MPa·m1/2 after the sintering pro-
C
cess. If the open-pored ZrO2 material is infiltrated with color-
ing liquids, its strength does not decrease [181,182] . The clinical
suitability of ZrO2 bridges made with the LAVA system has
been confirmed in scientific investigations. In these studies, the
frameworks were veneered with a silicate ceramic. Tribochemical
activation took place with SiO2 [183,184] .
Users of the Cercon system (TZP ceramic and feldspathic
layering material Cercon S) are advised to observe the recom-
mended dimensions of the connectors in three- to five-unit
bridges. These connector diameters should not fall short of Figure 6. Application of the veneering ceramic: sintering.
the following minimum values: 2.7 mm for three-unit bridges, (A) Clinical situation of the prepared teeth (14–16). (B) The same
4.0 mm for four-unit bridges and 4.9 mm for five-unit bridges. bridge (IPS e.max ZirCAD veneered with Ceram) on the dental
This precaution reduces the risk of below critical crack growth. technicians gypsum model. (C) Three-unit full-ceramic bridge
The restorations are expected to last approximately 20 years. The (IPS e.max® ZirCAD veneered with Ceram®) in clinical situation
(teeth 14–16).
recommended dimensions of ZrO2 frameworks are smaller than Dentist: A Stiefenhofer; dental technician: F Perkon.
those of lithium disilicate glass–ceramics [185,186] .
To enhance the IPS e.max materials system discussed previ- The IPS e.max Ceram glass–ceramic exhibits strength of
ously, a high-strength and high-toughness ceramic was developed, 90 ± 10 MPa, a linear CTE of 9.5 ± 0.25 × 10 -6 K-1m/m and
which is also veneered with fluoroapatite glass–ceramics [167,187] . very good chemical durability according to ISO 6872. IPS e.max
Therefore, a system of biomaterials was created that covers the Ceram is sintered on ZrO2 at a temperature of 760°C.
entire spectrum of indications for dental restorations, ranging IPS e.max ZirPress is molded at 910 °C. It demonstrates strength
from inlays, which are the most frequently produced restora- of 110 ± 10 MPa, a linear CTE of 9.75 ± 0.25 × 10-6 K-1m/m and
tions, to restorations for the anterior and posterior region of the very good chemical durability according to ISO 6872.
mouth. The high-strength 3Y2O3 –ZrO2 ceramic is called IPS In its porous state, the ZrO2 material is milled using the CEREC
e.max ZirCAD. It is veneered with the fluoroapatite glass–ceram- equipment and then densely sintered in the dental laboratory in
ics IPS e.max Ceram or IPS e.max ZirPress. Both fluoroapatite a special furnace, called Sintramat®, at 1500°C with a holding
glass–ceramics were developed in the SiO2–Al2O3 –Na 2O–K 2O– time of 30 min. After this processing step, the ceramic has the
ZnO–CaO–P2O5 –F system and contain needle-like fluoroapa- following properties: flexural strength of 900 ± 50 MPa, a linear
tite crystals. The solid-state reaction involved in the formation CTE of 10.75 ± 0.25 × 10 -6 K-1 m/m and very good chemical
of needle-like fluoroapatite glass–ceramics has been studied in durability (according to ISO 6872). The strengthening mecha-
detail in transmission electron microscopy (TEM) and nuclear nism of ZrO2 is based on the previously mentioned martensitic
magnetic resonance investigations. The growth of these crystals transformation [175,189,190] . After the ceramic has been machined
along the c-axis and the defect-free interface between the crystals and sintered, the dental technician has two options for applying
and the glass matrix have been analyzed with high-resolution the veneering ceramic: molding/pressing or sintering. The choice
TEM [188] . of the method depends on the final product and its geometry and

738 Expert Rev. Med. Devices 5(6), (2008)


Ceramics as biomaterials for dental restoration Review

on the working procedures used in the laboratory. Figure 5 (mold- bond can be achieved by carefully observing the experimental
ing/pressing) and Figure 6 (sintering) show the results achieved parameters in the joining of the glass–ceramic with the high-
with both of these techniques. The fact that minimally invasive performance ceramic [207] . However, if uncontrolled stresses do
preparation is required and that the materials are optimally fused occur, the glass–ceramic may chip or delaminate. Therefore, the
in the molding technique must be highlighted (Figure 5B) . procedure must be conducted with great care. Table 1 shows the
Only this kind of high-strength and high-toughness polycrys- advantages and risks for full-ceramic restorations.
talline ceramics veneered with glass–ceramics restoration offer In order to expand the application range of the materials system,
such esthetic solutions with the opportunity to save as much tooth it was supplemented with colored infiltration liquids. These liq-
structure as possible. uids impart ZrO2 frameworks with dental shades. Furthermore,
In the clinical case (Figure 5), the patient has lost the second pre- initial fundamental research results involving ZrO2 ceramics
molar (25) due to endodontic reasons. To replace the tooth there have shown that it is possible to produce ZrO2 ceramics in dental
are two possibilities, either a single dental implant or a fixed partial shades. The content of the coloring ions is very low but highly
denture. Owing to the small degree of damage to the first premolar, effective in imparting color [207] .
the author decided to restore the second premolar by means of a
hybrid-inlay and crown-retained fixed partial denture [191–197] . A Expert commentary & five-year view
high-strength zirconia framework was used because of good in vitro In the field of materials development, a number of avenues have
and short-term in vivo survival results [198–206] . The zirconia frame- been explored in an effort to produce materials that simulate the
work is designed and milled in a CAD/CAM process. This saves characteristics of natural teeth. In the process, special attention
time for the dental technician during the whole manufacturing has been paid to increasing the strength and toughness values
process. To achieve a good esthetic result, the opaque framework to the point that they exceed those of natural teeth, allowing
is veneered with glass ceramic by means of the press-on technique the materials to be used in the fabrication of sophisticated and
instead of veneering it with different ceramic pastes step-by-step esthetic bridgework. Dental materials are generally divided into
(as with IPS e.max ZirCAD veneered with Ceram presented in the following categories: materials for small or large restorations
Figure 6 ). This guaranteed that the glass ceramic surrounded the and materials for anterior or posterior teeth.
framework completely and, therefore, formed the marginal edge. The indications table (Table 2) clearly shows that the different types
On that condition the full ceramic bridge could be luted adhe- of glass–ceramics and high-strength ceramics available today already
sively. The individualization of the ceramic bridge was performed cover the entire range of indications of dental restorations. In some
by painting it. After try-in of the hybrid, full-ceramic bridge and cases, the information in this indications table is based on long-term
controlling for esthetics and function, it was luted adhesively. clinical experience with the different groups of materials.
Clinical studies have shown a survival rate of the framework The most important finding of the present publication, which
material of 99.1% and the veneering material of 97.1% after will play a significant role in the next 5 years, is the fact that the
34 months. Additional clinical results confirm the excellent bio- trend towards the development, fabrication and use of metal-free
compatibility of the restorations in a multicomponent composite restorations will continue to grow. Nevertheless, it is to be expected
system made of sintered ceramics and glass–ceramics. A defect-free that metal-reinforced restorations (especially long-span bridges)

Table 2. Indication of ceramics and glass–ceramics as biomaterials for dental restoration.


Clinical indication Ceramics and glass–ceramics Leucite Lithium disilicate Oxide ceramics
fused to metal framework glass–ceramics glass–ceramics
Copings – – + +
Inlays – + *
+ *

Onlays (partial coverage) – + *
+ *

Veneers – + *
+ *

Anterior crowns + +* + +
Posterior crowns + + *
+ +
Three-unit anterior bridges (up to + – + +
second premolar)
Three-unit posterior bridges + – – +
Bridges > 3 units + – – +
Inlay-retained bridges – – – +*
*
Adhesive cementation required.
+: Recommended.
– : Not indicated.

www.expert-reviews.com 739
Review Höland, Schweiger, Watzke, Peschke & Kappert

will retain their place alongside restorative biomaterials. Glass– Acknowledgement


ceramics are particularly suitable for fabricating inlays, crowns and Dedicated to Volker M Rheinberger on the occasion of his 60th birthday.
small bridges, as these materials achieve very strong, esthetic results.
High-strength ceramics are preferred in situations where the mate- Financial & competing interests disclosure
rial is exposed to high masticatory forces. In the field of ceramics, The authors are all employed by Ivoclar Vivadent AG; an international
developments are concentrating on the coloring of the materials to supplier of systems for the dental practice and the dental laboratory. The
enhance their smooth integration in the natural dentition. authors have no other relevant affiliations or financial involvement with
The processing technologies to watch in the future include sin- any organization or entity with a financial interest in or financial conflict
tering, molding and machining. The trend towards machining with the subject matter or materials discussed in the manuscript apart from
techniques continues to develop strongly. Therefore, comprehen- those disclosed.
sive clinical studies and extensive training of dentists and dental No writing assistance was utilized in the production of this review
technicians are required. manuscript.

Key issues
• Clinical studies to identify the indications of biomaterials for restorative dental applications are ongoing.
• Joining and connecting of different materials achieves the best possible mechanical and optical properties and long-term service life of
dental restorations.
• Optimization of processing techniques will enable efficient and precision fabrication of restorations.
• Training of professional staff to handle and use materials properly is necessary.
• Continuation of the trend towards completely treating the patient in few or, if possible, in one appointment is anticipated.
• Development and use of minimally invasive techniques in restorative dentistry will hopefully become a reality.

10 Hench LL, Bioceramics: from concept to 19 Lindemann W. Kristalline Phasen in


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