Additive manufacturing of lithium disilicate glass-ceramic by vat polymerization for dental appliances.

OBJECTIVES: The objectives of this study were to evaluate the mechanical properties of lithium disilicate components produced by additive manufacturing (AM) and to assess the effect of build orientation on the resistance to fracture. METHODS: Oversized bars were printed with a glass-filled photoactive resin using a digital light processing technique. After sintering and post-processing, flexure and chevron notch fracture toughness bars were obtained in three principal orientations (0°, 45°, and 90°) with respect to the build direction. Mechanical properties were obtained according to the relevant ASTM standards. The hardness, indentation fracture resistance, and elastic modulus were measured for each orientation, and a Weibull analysis was conducted with the flexure responses. Fractography of the fracture surfaces was performed to identify the failure origins. RESULTS: The 0° orientation exhibited characteristic strength, Weibull modulus, and elastic modulus of 313 MPa, 4.42, and 168 ± 3 GPa, respectively, which are comparable to lithium disilicate materials from traditional processes. However, build orientation contributed significantly to the flexure strength, elastic modulus, and Weibull modulus; the characteristic strengths for the 45° and 90° build orientations were 86 MPa and 177 MPa, respectively. The primary contribution to the orientation dependence was the number of residual build layer-related flaws from incomplete union between printed layers. Of note, hardness and the fracture toughness were not dependent on build orientation. SIGNIFICANCE: AM of lithium disilicate materials can achieve the mechanical properties of materials produced by traditionally processing. Thus, while further process development is warranted, the outlook for dentistry is promising.

Vat Polymerization-Printed Partially Stabilized Zirconia: Mechanical Properties, Reliability and Structural defects.

Additive manufacturing (AM) of ceramics, particularly of zirconia, is becoming of increasing interest due to the substantial freedom available in the design and fabrication process. However, due to the novelty of the field and the challenges associated with printing dense bulk ceramics suitable for structural applications, thorough investigations that explore the effects of printing on the mechanical performance are limited. Previous work has identified anisotropy in the mechanical properties and attributed it to the layer-by-layer deposition. However, substantiated fractographic evidence detailing the origins and effects of layer lines on the probability of failure are limited. This study investigates the mechanical properties of a dense (>99 %TD), partially stabilized zirconia fabricated by a digital light projection printing method following ASTM standards. Hardness and strength evaluations were conducted, followed by a Weibull analysis and fractography. The investigation entailed five unique build directions and a conventionally manufactured reference material that was used as a control. Although the strengths were comparable to the reference material for some orientations, fracture frequently initiated at layer lines and related defects in all orientations. The findings indicate that if the layer lines can be prevented or engineered, the strength of vat printed ceramics can be improved substantially.