Engineers at the University of Texas at Dallas have developed a new method for producing same-day dental restorations using 3D printing and zirconia, a strong ceramic material commonly used for crowns and bridges. This innovation could transform dental care by allowing patients to receive permanent restorations in a single visit, rather than waiting days or weeks.
Traditional zirconia restorations require a lengthy process that includes debinding to remove resin binders and high-temperature sintering to harden the material. This can take up to 100 hours, making it impractical for same-day service. The UT Dallas team solved this problem by using porous graphite felt and enhanced heat transfer to reduce debinding time to under 30 minutes. A vacuum system helps remove gases during heating, preventing cracks and fractures in the final product.
The new method allows for custom-printed crowns, bridges, and veneers that match the patient’s anatomy and color. It also reduces waste and manufacturing costs compared to milling, which carves restorations from solid blocks. The printed zirconia parts are strong, biocompatible, and aesthetically pleasing, making them suitable for long-term use.
Take a look at this brief video about the process:
Article from UT Dallas: Crown Jewel of Dental Restoration Technology May Be in Sight
Abstract in Ceramics International: Single-step thermal debinding for ceramics vat photopolymerization in less than 30 minutes
