Thickness and internal adjustment of monolithic resin composite milled crowns: Effect on the load-bearing capacity under fatigue

Objectives: To evaluate the fatigue failure load (FFL), cycles for fatigue failure (CFF) and survival rates of different occlusal thicknesses of resin composite simplified crowns with internal adjustments (IA) or without as control (C). Methods: 30 monolithic simplified crowns of CAD/CAM resin composite (Tetric CAD, Ivoclar) were milled in three different occlusal thicknesses (0.5 mm, 1.0 mm, and 1.5 mm). Half of the crowns were submitted to restricted adjustment with diamond burs on the crown's inner surface and half remained milled without internal adjustment. The samples were treated and adhesively luted onto a prosthetic preparation made of epoxy resin reinforced by glass-fiber substrate. The sets were subjected to a fatigue test (cyclic fatigue: initial load of 200 N; step-size of 50 N; 10,000 cycles/step; 20 Hz; maximum load: 2800 N).Microscopic analysis of tested representative samples was performed. The fatigue data were statistically analyzed (α= 0.05) and the micrograpic images were qualitatively evaluated. Results: All specimens from groups 1.0C and 1.5C survived the cyclic loads, while all 0.5C samples failed during the test. The 1.0IA and 1.5IA crowns showed no statistical difference for FFL (2530 N= 2670 N) and CFF (471,000 cycles= 499,000 cycles) between them, and they were both statistically superior to the 0.5IA (FFL= 1812.50 N; CFF= 327,500 cycles). The 1.0 mm and 1.5 mm crowns presented superior fatigue behavior (2530 N–2800 N) compared to the 0.5 mm crowns (1812 N–2140 N), whether internal adjustment was performed or not. A statistically significant difference was found for FFL and CFF of 0.5 mm crowns with and without internal adjustment, with a deleterious impact of the adjustment for both parameters (FFL and CFF: 0.5C > 0.5IA). Significance: Resin composite milled crowns can bear high cyclic fatigue loads despite thickness, although thicker crowns had better mechanical behavior; however, the internal adjustment in the composite resin crown leads to a detrimental effect on its fatigue behavior, which presents a risk of mechanical failure due to premature fatigue.