Five-axis laser milling system that realizes more accurate zirconia CAD/CAM crowns by direct milling from fully sintered blocks.

Directly milling zirconia computer-aided design (CAD)/computer-aided manufacturing (CAM) crowns from fully sintered zirconia blocks using a five-axis laser milling system, compared with three-axis milling and full sintering by heating milled semi-sintered crowns, was investigated. The mechanical characteristics of zirconia specimens were similar across groups. The order of the marginal gap was three-axis>conventional (lingual thickness of 1.5 mm>0.5 mm)>five-axis group (close to zero). The marginal shape was almost perfectly circular in all groups. The internal corner shape and gap were almost perfect for the five-axis milled crown but not for conventional and three-axis crowns. The roundness of the marginal and internal shapes was almost perfect in the five-axis milling group but not for the three-axis and conventional groups. These small distortions result in large marginal gaps. Results of the present study suggest the superiority of the five-axis milling system in creating a zirconia prosthesis.