At Catalis Dental Lab Partners, with locations in Phoenix, Arizona and Warren, Michigan, material selection is one of the most critical decisions in fabricating durable and esthetic restorations. As restorative and prosthetic dentistry evolves with digital workflows and 3D printing technology, clinicians and lab technicians must collaborate to choose materials that align with each case’s functional, anatomical, and esthetic needs.
Among the most commonly requested materials in modern dental labs are zirconia and lithium disilicate. Both are highly advanced ceramic materials, each offering distinct benefits for strength, appearance, and clinical versatility. Yet, understanding when to use one over the other can make a significant difference in long-term success. This blog provides a comprehensive comparison to help dental professionals make informed decisions for their patients.
What Is Zirconia?
Zirconia, or zirconium dioxide, is a ceramic material known for its exceptional strength and biocompatibility. First introduced in dentistry for crowns and bridges in the early 2000s, zirconia has evolved from opaque, functional restorations to more translucent and esthetically pleasing versions such as 3Y-TZP, 4Y-PSZ, and 5Y-PSZ.
Zirconia restorations are commonly milled from pre-sintered blocks using CAD/CAM technology, which allows for precise internal fits and contouring. Once milled, zirconia must undergo sintering in a high-temperature furnace, which finalizes its hardness and translucency. For high-stress areas such as posterior bridges or patients with bruxism, zirconia is often the material of choice due to its fracture resistance.
Recent advancements have made multi-layered zirconia blocks with varying translucency and shading available, improving their appearance while maintaining functional durability. At Catalis, these materials are optimized through 3D digital workflows and custom coloring for natural-looking restorations.
What Is Lithium Disilicate?
Lithium disilicate is a glass-ceramic material widely celebrated for its esthetics. It is typically used for anterior restorations, veneers, and inlays/onlays due to its ability to mimic the light transmission of natural enamel. The material is available in both pressable and millable forms, with CAD/CAM applications being especially popular for their consistency and precision.
Restorations made with lithium disilicate—such as IPS e.max—are prized for their translucency, making them suitable for cases where esthetics are paramount. While its strength is lower than zirconia, with flexural strength around 400 MPa compared to zirconia’s 900–1200 MPa, lithium disilicate still provides adequate durability for most single-unit restorations.
At Catalis Dental Lab, technicians use lithium disilicate to achieve lifelike details, such as layered incisal edges and customized surface texture, providing exceptional esthetic results for demanding cosmetic cases.
Comparing Material Properties
Key Differences Between Zirconia and Lithium Disilicate:
- Strength: Zirconia is significantly stronger and more fracture-resistant, ideal for posterior restorations and bruxism patients.
- Esthetics: Lithium disilicate offers superior translucency and enamel-like characteristics, making it better suited for anterior teeth.
- Preparation Design: Zirconia allows for more conservative preparations due to its strength; lithium disilicate requires more thickness for optimal results.
- Cementation: Lithium disilicate is typically bonded with resin cement, enhancing retention and strength; zirconia can be cemented conventionally or bonded.
- Versatility: Zirconia can be used for full-contour crowns, bridges, implant abutments, and more; lithium disilicate is preferred for veneers, inlays, and anterior crowns.
These factors are carefully evaluated by Catalis technicians, who communicate closely with dentists to ensure each case is handled with optimal materials based on clinical indications and patient expectations.
Clinical Indications and Case Selection
The decision between zirconia and lithium disilicate is highly case-dependent. For full-coverage posterior crowns where strength is a top priority, zirconia is the preferred choice. This includes patients with limited interocclusal space, history of grinding, or when fabricating long-span bridges.
Conversely, for anterior teeth—especially where minimal tooth reduction and translucency are required—lithium disilicate is typically the material of choice. It performs well for single crowns, veneers, and conservative onlay restorations, particularly when supported by enamel for ideal bonding.
Catalis clinicians in Phoenix and Warren benefit from personalized case consultations to determine material choices. The lab’s digital capabilities allow for virtual mockups and restorability assessments prior to fabrication, ensuring case predictability.
Workflow Optimization Through Digital Tools
Material choice is deeply intertwined with digital workflows. Catalis Dental Lab incorporates intraoral scans, digital smile design, and 3D printing to create restorations that integrate seamlessly into the patient’s existing anatomy.
Once a scan is submitted, the lab uses CAD software to design the restoration with the selected material’s requirements in mind. Zirconia and lithium disilicate differ in milling parameters and finishing processes, so proper design planning is essential. For instance, connector thickness for bridges must be greater for lithium disilicate than zirconia.
Post-design, the lab determines the best path forward: zirconia restorations are sintered and stained, while lithium disilicate is crystallized and then characterized for a natural finish. These carefully monitored steps ensure the final result is strong, esthetic, and precisely fitting.
Material Selection in the Context of 3D Printing
Although zirconia and lithium disilicate are not 3D printed themselves, 3D printing plays a critical supporting role in their production. At Catalis, 3D printed models are used to verify crown fit, marginal integrity, and occlusion prior to final delivery.
For implant cases, 3D printing is instrumental in producing accurate surgical guides, custom abutment replicas, and provisional restorations. This helps bridge the gap between digital design and real-world application, improving patient safety and satisfaction.
In cosmetic cases where lithium disilicate is used, 3D printed mockups and wax-ups help the clinician and patient visualize the outcome before any preparation is done. This approach increases case acceptance and patient confidence.
Customization and Patient Expectations
Patients today are more informed and have higher expectations for both esthetics and function. Catalis meets these expectations by offering shade matching, digital smile previews, and custom layering techniques. Whether the patient’s concern is achieving a natural smile or maintaining strength during chewing, the right material choice paired with precision lab work can meet those demands.
In Phoenix and Warren, where Catalis serves a diverse patient population, clinicians often need a balance of strength and esthetics. The lab’s guidance ensures that every case—whether it involves a full-arch zirconia restoration or a single lithium disilicate veneer—is tailored to the individual’s anatomy, bite, and smile goals.
Making the Right Decision with Catalis
When clinicians work with Catalis Dental Lab, they gain a partner committed to helping them deliver results they can stand behind. The decision between zirconia and lithium disilicate isn’t simply about the material—it’s about the long-term success of the restoration.
Catalis supports dentists with consultations, material samples, preparation guidelines, and digital design assistance. Every case receives hands-on attention, ensuring not only technical excellence but clinical relevance. This collaborative approach helps practitioners in Phoenix and Warren grow their practices and exceed patient expectations.
Elevate Your Cases with Expert Guidance
Choosing between zirconia and lithium disilicate should never feel like a guessing game. At Catalis Dental Lab Partners, clinicians receive the benefit of advanced material science, cutting-edge digital workflows, and decades of combined experience in restorative dentistry.
By understanding the clinical scenarios best suited to each material, dentists can offer treatments that last longer, look better, and require fewer adjustments. When the right material is chosen from the start, everyone—from the clinician to the patient—wins.
Resources
Guess, P. C., Schultheis, S., Bonfante, E. A., Coelho, P. G., Ferencz, J. L., & Silva, N. R. F. A. (2015). All-ceramic systems: Laboratory and clinical performance. Dental Clinics of North America
Kelly, J. R., & Benetti, P. (2011). Ceramic materials in dentistry: Historical evolution and current practice. Australian Dental Journal
Gracis, S., Thompson, V. P., Ferencz, J. L., Silva, N. R., & Bonfante, E. A. (2015). A new classification system for all-ceramic and ceramic-like restorative materials. The International Journal of Prosthodontics
