Marginal and Internal Fit of Zirconia Crowns with Varying Yttria Content and Finish Line Configurations: An In Vitro Study

Aim: This in vitro study aimed to evaluate the marginal and internal fit of three monolithic CAD/CAM zirconia ceramics with different Y-TZP contents, prepared with chamfer and rounded shoulder finish lines. Methods. Sixty zirconia crowns were fabricated and equally divided into three material groups, each further subdivided into chamfer and rounded shoulder designs. Marginal and internal gaps were assessed using the silicone replica technique under a stereomicroscope by a single operator. Statistical analysis was performed with three-way ANOVA and Tukey’s post hoc test (p < 0.05). Results: The occlusal region exhibited the largest gap values, while the axial region showed the smallest across all groups. Mean marginal and internal gaps were 33.79 µm for chamfer and 43.37 µm for rounded shoulder finish lines. Zirconia with higher Y-TZP content demonstrated significantly greater gap values than those with lower percentages (p < 0.05). Significant interactions were found among finish line design, material type, and measurement region (P < 0.05), with rounded shoulder margins showing larger gaps (p = 0.001). Conclusions: Y-TZP content significantly affects marginal and internal adaptation, with higher percentages associated with increased gap values. Both finish line types produced clinically acceptable fits, although chamfer margins provided superior adaptation.