New tech 3D-prints durable zirconia dental crowns in just hours

Researchers at the University of Texas at Dallas have developed a groundbreaking 3D-printing technology that enables the production of permanent zirconia dental crowns in just a few hours, potentially allowing patients to receive same-day restorations. Zirconia is considered the gold standard for durable dental work, but traditional manufacturing methods, such as milling, limit design complexity and risk micro-cracking. Existing 3D-printed crowns use ceramic resins that lack zirconia’s strength. The key innovation lies in drastically reducing the debinding process—from 20-100 hours to under 30 minutes—by using porous graphite felt, enhanced heat transfer, and a vacuum system that safely removes gas during resin burnout, preventing cracks and fractures. This advancement not only accelerates the production timeline but also offers stronger, more customizable dental restorations compared to resin alternatives and milled zirconia. The technology promises to lower waste and costs while improving patient experience by enabling dentists to provide permanent crowns, bridges, and veneers chair-side in a