Advances in patterned interface design and bonding performance of 3D-printed dental zirconia ceramics: a review

Abstract

Zirconia ceramics have emerged as a mainstream material in dental restorations due to their excellent mechanical and aesthetic properties. However, their inherent chemical inertness and lack of glass phase result in insufficient interfacial bonding stability, creating a critical constraint for clinical applications. Traditional surface treatments are prone to triggering sur/subsurface microcrack propagation, substantially compromising the intrinsic strength of zirconia ceramics. In contrast, emerging surface patterning techniques enable precise engineering of micro/nanoscale topological constructions, allowing modulation of interfacial wettability, stress distribution, and bioactive response characteristics of materials. This biomimetic approach provides an innovative strategy to resolve the challenges of zirconia interface bonding. Currently, additive manufacturing is one of the mainstreams for surface pattern preparation, demonstrating unique advantages in achieving customized morphology construction and performance optimization. This review focuses on the recent progress in the application of 3D printing technologies in the field of surface patterning of zirconia-based ceramics. It primarily explores the structure–property relationships between process, structure, and performance, and systematically reviews the breakthrough directions and development challenges of the current research paradigm.