The dental crown of the future could be 3D-printed while you wait

A new technology developed at the University of Texas at Dallas could make it possible for dentists to 3D-print permanent zirconia dental restorations in a single day. Zirconia is a strong and durable material often used for permanent dental work, including crowns, bridges, and veneers. The researchers, supported by the National Science Foundation (NSF), aim to commercialize the technology for use in various dental restorations.

Dr. Majid Minary, a professor of mechanical engineering, highlighted the benefits of this approach, including greater personalization, faster treatment, and the convenience of receiving a permanent restoration in one visit. Dental crowns, which are protective caps for damaged teeth or used to support dental bridges, are typically made from ceramic resins.

While same-day 3D-printed crowns exist, they are usually made from ceramic resins, which lack the strength of zirconia. Traditional 3D-printed zirconia restorations require time-consuming debinding and sintering processes, often taking 20 to 100 hours. The new UT Dallas technology significantly reduces the debinding stage to less than 30 minutes, potentially overcoming one of the main barriers to same-day permanent zirconia dental restorations.

The system uses improved heat transfer and porous graphite felt to facilitate gas escape during debinding and remove gases via a vacuum system. With this technology, dental practitioners could potentially provide chair-side 3D-printed zirconia crowns within a few hours. The research team is currently collaborating with Pan-AM Dental Laboratory, 3DCeram Sinto Inc., and Dr. Amirali Zandinejad to move the technology toward commercialization.

The NSF and the U.S. Air Force Office of Scientific Research have provided support for this project.