Forming capability of advanced customized jetting additive manufacturing for restorations with different margin morphologies and surface textures.

Objectives: This study aims to investigate the forming capability of Advanced Customized Jetting (ACJ) technology for four different margin types restorations and five surface textures.

Materials and methods: Zirconia restorations with four margin types (heavy-chamfer, chamfer, shoulder and biologically oriented preparation technique (BOPT)) were fabricated using CAD/CAM and ACJ technology (n = 10), then compared the root mean square (RMS) at non-marginal and Marginal regions. Surface textures were designed on 5 mm×5 mm× 5 mm cubes, including 11 groups: 1 non-porous (NP) group and 10 experimental groups with circular, triangular, square, pentagram, or hexagonal textures at 400 μm (D₄) or 800 μm (D₈) apertures (n = 10). ACJ fabricated textured samples were analyzed via SEM and 3D profilometry and measured dimensional accuracy along X/Y/Z axes.

Results: (1) All ACJ restorations have lower RMS values at non-marginal regions than CAD/CAM (P < 0.01). ACJ fabricated heavy-chamfer, chamfer and BOPT restorations have lower RMS values at marginal region than CAD/CAM (P < 0.01), whereas no difference in shoulder (P > 0.05). (2) Circle and hexagon have the highest accuracy: D₄C (90.58%), D₈C (94.96%), D₄H (87.29%) and D₈H (92.96%), while pentagram has the lowest accuracy (D₈P: 71.37%). The dimensional deviations of Z-axis are within 10 μm, and the accuracy of printing are above 90%.

Conclusions: ACJ restorations exhibited lower RMS values than CAD/CAM in both non-marginal region and marginal region with heavy-chamfer, chamfer, and BOPT margins. Circle textures have the highest accuracy and larger aperture improves printing accuracy.

Clinical relevance: ACJ fabricated zirconia restorations exhibit higher geometric precision and demonstrate technical feasibility in manufacturing customized morphological features.