Stress Distribution of Monolithic and Veneered 3-unit Zirconia FDPs—Finite Element Analysis

To evaluate the effect of restoration design on fracture resistance and stress distribution of veneered and monolithic 3-unit zirconia fixed partial dentures (FDPs) using finite element analysis (FEA).Identical epoxy resin replicas of mandibular second premolar and second molar (to serve as abutment for the 3-unit bridge) were divided into four groups (n = 10): monolithic zirconia (MZ) restorations; conventional layering veneering technique (ZL), heat-pressed technique (ZP), or CAD/CAM lithium disilicate glass ceramic (CAD-on). Specimens were subjected to compressive cyclic loading on the mesio-buccal cusp of the pontic (load range 50 to 600 N; aqueous environment; 500,000 cycles) in a universal testing machine. Data were statistically analyzed at 5% significance level with Fisher exact test and Kaplan-Meier survival analysis. 3D models were constructed in accordance with experimental groups. The stress distribution in each model was analyzed and evaluated according to the location and magnitude of the maximum principal stresses (MPS) using ANSYS software.Specimens from ZL and ZP groups failed at different stages of the 500,000 cycles fatigue, while CAD-on and MZ restorations survived fatigue test. Statistically, there was a significant difference between the groups (P < .001). The MPS were located under the mesial connector in both monolithic and bilayered 3-unit zirconia FDPs. These stresses were found to be higher in monolithic geometries compared to bilayered zirconia FDPs.Monolithic 3-unit zirconia and CAD-on zirconia frameworks resulted in superior fracture resistance. Restoration design significantly affected the stress distribution of 3-unit zirconia FDPs.