Purpose: The aim of this study was to evaluate the marginal and internal fitness of PEEK and Zirconia crowns fabricated by three different impression techniques. Materials and methods: Thirty standardized acrylic die models were prepared. Dies were divided into two main groups (n= 15): Group 1: CAD/CAM fabricated zirconia crowns. Group 2: CAD/CAM fabricated PEEK crowns. Each group was subdivided into three subgroups (n= 5), according to the impression technique using for data acquisition: Sub-group (A): direct digital scans of the model used intraoral digital scanner. Sub-group (B): indirect digital scans of the silicon impressions using extraoral scanner. Sub-group (C): indirect digital scans of the stone casts obtained from silicon impressions using extraoral scanner. Crowns were then designed and fabricated. Marginal and internal gaps were measured using silicone replica technique and field digital microscope. Results: Independent t-test was used for comparison between groups. Comparisons between subgroups were performed by one-way analysis of variance (ANOVA) test, followed by Bonferroni’s post hoc test. In Zirconia group, the highest mean value was recorded in stone cast scan group, followed by intraoral scan, with the least value recorded in impression scan subgroup. In PEEK group, the highest mean value was recorded in stone cast group, followed by impression scan, with the least value recorded in intraoral scan subgroup. Conclusions: All tested crowns showed marginal gap distance values within the clinically acceptable levels. PEEK crowns had lower vertical marginal gap distance than zirconia crowns with different scanning techniques.
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