Preparation of presintered zirconia blocks for dental restorations through colloidal dispersion and cold isostatic pressing

This work proposes an effective method for dispersion of zirconia suspension for dental block preparation and optimizes the cold isostatic pressing (CIP) pressure to improve the densification of slip-casted zirconia blocks. Two batches of 44 wt% zirconia suspension were prepared using distilled water in a pH 2 medium containing 0.5 wt% polyethyleneimine as dispersant. The first batch was sonicated for different durations (from 5 min to 30 min), and the second batch was dispersed through ball milling at rotational speeds of 200, 300, and 400 rpm for 60, 90, and 120 min. All suspensions were subjected to sedimentation test and particle size measurement. Results revealed that the optimum ultrasonication duration was 10 min, which yielded the smallest particle size of 133 nm. Ball milling at 300 rpm for 120 min achieved the maximum dispersion of particles, with an average size of 75 nm. Under the optimum conditions of ultrasonication duration, ball milling duration, and ball milling speed, the particle size decreased to 48 nm, which is close to the primary particle size. These dispersion techniques and parameters were selected for preparing a suspension to be consolidated into blocks through slip casting and were enhanced through CIP at pressure ranging from 100 MPa to 300 MPa. CIP compaction at 250 MPa significantly increased the shrinkage percentage of green zirconia blocks, with pore radius decreased to 18 nm. The density of zirconia pressed at 250 MPa and presintered at a low temperature of 950 °C was 59% of the theoretical density and was higher than that of commercial presintered blocks. Thus, CIP should be conducted under a compaction pressure of 250 MPa to produce dense and homogeneous zirconia blocks.