Retrospective 2-to 7-Year Follow-Up Study of 20 Double Full-Arch Implant-Supported Monolithic Zirconia Fixed Prostheses: Measurements and Recommendations for Optimal Design

PurposeTo measure the extension of cantilever lengths, thicknesses, and heights of zirconia prostheses in the lingual and facial areas of the distal screw access openings, and to evaluate the clinical performance regarding chipping or fracture of the distal cantilevered sections of double full-arch CAD/CAM screw-retained, stained, monolithic zirconia, gingival-colored ceramic implant-supported fixed prostheses (MZ-FPs). Materials and MethodsTen edentulous patients were provided with a total of 20 CAD/CAM double full-arch MZ-FPs. The zirconia thicknesses around distal screw access openings at three different levels (crown height space, screw access opening lengths, and dimensions of the cantilevered segments) were measured in the resin prototypes. Patients were evaluated clinically (visually) without magnification, with intraoral digital photography, and radiologically by the author, approximately every 6 months. Ten patients with 20 MZ-FPs were evaluated. Twenty resin prototypes with 35 cantilevered segments (15 maxillary, 20 mandibular) were measured. The lingual and facial thicknesses of the resin frameworks and the crown height spaces of 35 distal access openings were measured. ResultsThe average extension of the maxillary cantilever segments was 7.72 mm; the mandibular cantilever average was 13.72 mm. The average crown height space for maxillary prostheses was 13.27 mm, for the mandibular prostheses it was 11.89 mm. Zirconia thickness around distal screw access openings at the middle of the crowns, margins and middle of the gingival areas (buccal side of maxillary prostheses) was 4.29, 3.79, and 3.87 mm, respectively. On the lingual sides the thicknesses were 3.13, 2.85, and 3.15 mm, respectively. For mandibular prostheses the thicknesses were 3.56, 3.08, and 3.15 mm, respectively, on the buccal sides, and 2.07, 2.00, and 2.99 mm, respectively, on the lingual sides. No implant failure or changes in the occlusal surface, chipping of the cuspid or incisal edges, or prosthesis distal extension fractures were observed during follow-up periods ranging from 2 to 7 years. The survival rate was 100% for implants and prostheses. In one of the patients, chipping of the pink ceramic was noted in the maxillary prosthesis 36 months after placement. ConclusionsThe results of this study indicated that full-arch MZ-FPs without cutback, or with partial digital cutback and veneering ceramic, were a therapeutic option. Recommendations regarding the thickness of zirconia at the level of the distal screw access openings, the crown height spaces, and the lengths of the cantilever segments were recorded. Additional in vitro and clinical studies will be required for more scientific analysis of the criteria for design of this type of prosthesis to minimize prosthetic complications. Long-term and multicenter studies are needed to corroborate the findings discussed in this report.