Frequently Asked Questions

General Information

As a restoration can be made right away in the dental clinic after designing, making it possible to cement it in the patient’s mouth on the same day of their visit.  In this way it reduces the number of patient appointments while achieving predictably high levels of success and patient experience.

It is validated for use with the Dentsply Sirona CEREC® system, which includes a digital impression scanner, a design software, a manufacturing unit, and a sintering furnace.  Please consult with your local CEREC® representative for detailed information on configuration.

Size 12Z and 14Z single unit blocks are available in software versions 4.5.2 and above, while 14ZL bridge block is available in software version 5.1 and above.

A total of 14 shades:  Super Translucent Multi Layered 14 Shades (Noritake White, A1, A2, A3, A3.5, A4, B1, B2, B3, C1, C2, C3, D2, D3)

No.  It is based on the VITA Classical Shade Guide.

Kuraray Noritake has designed KATANA™ Zirconia STML multi-layer block utilizing its unique pigment technology.  As a result, the product consists of four layers of zirconia in gradated shades. Translucency is gradually decreased from the incisal to the cervical region, to increase the masking level in the cervical region.  They are arranged in the order of 35% (Enamel Layer), 15%, 15%, (Transition Layer 1 and 2) and 35% (Body Layer).  Please refer to the product catalog for details.

Some other factors to consider when choosing the shade are the shade of the abutment and the surrounding teeth, thickness of the restoration, placement of the restoration, and the finishing technique using either polishing or glazing.

KATANA™ Zirconia block is indicated for anterior full single crowns, posterior full single crowns, veneers, inlays and onlays. Please refer to the product catalog for details.

Kuraray Noritake Dental recommends the following material thickness based on the following indications:
Anterior crown 0.8mm; Posterior crown 1.0mm; Inlay 1.0mm; Onlay 1.0mm including functional cusp; veneer 0.4mm. 
For the bridge block:  connectors should be >12mm2 for anteriors and > 16mm2 for posteriors. 
Chamfer and shoulder margins are recommended.

Single unit blocks come in two sizes (12Z and 14Z).  Single unit blocks are used to fabricate posterior crowns, anterior crowns, veneers, inlays and onlays. The bridge block (14ZL) may be used to fabricate a bridge up to 2-3 units.

The dimensions of the blocks sizes before it has been sintered are:

15.3mm (H), 19.2mm (W), 20.2mm (L) for 12Z blocks
17.8mm (H), 19.2mm (W), 20.2mm (L) for 14Z blocks
17.8mm (H), 19.2mm (W), 40.0mm (L) for 14ZL bridge

After sintering, the actual size of the restoration will be changed to shrink roughly 80% of each block size. The dimensions of the blocks sizes after it has been sintered are:

12.2mm (H), 15.4mm (W), 16.2mm (L) for 12Z blocks
14.2mm (H), 15.4mm (W), 16.2mm (L) for 14Z blocks

The CEREC® software will determine if a proposed bridge restoration design will successfully transfer the job from the manufacturing unit to the furnace, since the insulation platform of the Speedfire is only <38mm in diameter.

As 12Z provides 12mm height after sintering, the majority of crowns will be covered when using the 12Z size.  KATANA™ Zirconia 14Z can be used for taller crowns.

KATANA™ Zirconia is tested up to 859MPa flexural strength.

KATANA™ Zirconia has a high mechanical strength (>763 MPa). This product has a multi-layered structure (color gradients) so it is easier to fabricate a more natural looking restoration. In contrast with glass ceramics, thinner restorations are possible, to provide more conservative dentistry.  KATANA™ Zirconia can be milled in 4 minutes utilizing the Primemill’s Super Fast mode.  It has higher translucency, as well as a multi-layered structure, thereby making it easier to fabricate a more natural looking restoration simply by polishing.  By eliminating the extra steps of staining and glazing, this reduction in time allows for fast and efficient single-visit dentistry.  Our product is made with our proprietary Kuraray Noritake zirconia raw materials , which allows for a short sintering time of 18 minutes in the Speedfire furnace.  Finally, cementation is simplified when used in conjunction with other Kuraray Noritake products.

KATANA™ Zirconia Processing

(Please refer to the CEREC Owners Manual for additional information)

Yes. We strongly recommend using dry milling. It is possible to mill this product using wet milling with clean cooling water but tank cleaning and filter changing are necessary before using if you change to zirconia milling from another material. Furthermore, because the drying process is necessary, the sintering time becomes 43 minutes.

< 5mins with the Primemill’s Super Fast milling mode

No. If it is the same size, the processing (milling) time is the same.  You may notice a longer manufacture time if your burs are dull, or needs replacement.

When the barcode or QR code scanning fails, please manually add the 7 character code from the block. If there are only six characters, please press the <SPACEBAR> to add “space” at the end.

Milling from the following serial numbers are “Dry Ready”. This means they have integrated vents in the milling chamber, thus can be used for dry milling without any retrofitting:

CEREC® MC: 202544
CEREC® MC X: 237931
CEREC® MC XL Premium Package: 305680

Milling units from the following serial numbers are “Dry Prepared” and can be retrofitted to “Dry Ready” for dry milling zirconia with a CEREC® Suction Unit

CEREC® MC: 202501
CEREC® MC X: 236001
CEREC® MC XL PP: 304801

A retrofit kit can be ordered for “Dry Prepared” units which includes all necessary components for dry milling zirconia. The retrofit can be completed in the field by a technician and takes about 45-60 minutes.  Unfortunately, milling units produced before these serial numbers cannot be retrofitted to “Dry Ready”.

Additionally, an acquisition scanner (Omnicam or Primescan), CEREC® design software 4.5.2 and above, a SpeedFire furnace, and suction unit is necessary. Consult with your local CEREC® Sales Rep for detailed information.

We strongly recommend using dry milling. Milling is done by using a carbide bur under both dry and wet conditions. Grinding is done with a diamond bur under wet conditions. If the customer selects the Milling option, and the machine is a properly equipped dry-milling units, the CEREC® machine will automatically start with the dry-milling condition. If there is a mismatching between the “milling/grinding’” selection, and the “Wet/Dry bur” selection, the machine does not allow the customer to have the milling option to avoid problems. It is possible to mill this product using wet milling with clean cooling water but tank cleaning and filter changing are necessary before using. Furthermore, because the drying process is necessary, the sintering time becomes 43 minutes.

No, there are no qualitative differences between wet milling and dry milling. Accuracy and detail of the result are identical in both processes. There are also no differences in processing times between wet and dry milled restorations. Only the pre-drying time during sintering of zirconium oxide is eliminated with dry-milled restorations.

Debris from glass ceramics could have a negative effect in color and translucency for KATANA™ Zirconia;

We recommend using three separate tanks:   1. a dedicated glass ceramic cooling-water tank, 2. a water tank for flushing in between restorations, and 3. a dedicated zirconia cooling-water tank

Particles from other block materials (e.g. lithium disilicate, feldspathic, etc.) may affect the shade and translucency of KATANA™ Zirconia while wet milling in the green state; therefore, preparing a separate water chamber for zirconia is optimal.  Remove tank #1, and insert tank #2.  Flushing the mill for 10-30 seconds is recommended prior to wet-milling the zirconia to prevent contamination of materials that have circulated through the unit.  Insert tank #3 to begin the wet-milling process of KATANA™ Zirconia

If you are using KATANA™ Zirconia with other block materials in the same milling unit, and are utilizing only one water tank, it is recommended to replace the filter, as well as replace the cooling liquid. Insufficient cleaning of the chamber or filter may result in a restoration with lower translucency or result in a chalky appearance. 

If it occurred during “wet milling/grinding”, it was more than 90% caused by ceramic contamination.

It depends on clinical cases. Consult the Manufacturing unit’s Operating Instructions manual.

Please check that the block is set at the desired position. If screwing is insufficient, the block will move from desired position and unnecessary force will be applied and may cause the restoration to break as it is being milled. If the setting of the block has a problem, please contact your distributor.

Milling:
Dry: Carbide (Shaper 25 and Finisher 10); Wet: Carbide (Shaper 25RZ and Finisher 10)
Grinding:Only Wet (no dry-mode): Diamond (Step Bur 20 and Cylinder Pointed Bur 20)
Consult the Manufacturing unit’s Operating Instructions manual

The initial positioning calculated by the machine is the best milling time /stable milling condition from a milling strategy point of view.In some cases, it is necessary to have proper adjustments between the tooth shape and multi-layer position later on from an esthetic point of view.

The dimensions of a final restorations (post-sintered) fit in the following blocks sizes:

12.2mm (H), 15.4mm (W), 16.2mm (L) for 12Z blocks
14.2mm (H), 15.4mm (W), 16.2mm (L) for 14Z blocks
14.2mm (H), 15.4mm (W) for 14ZL bridge blocks and <38mm in length to fit in the SpeedFire oven.

The proper KATANA™ Zirconia block size was not chosen in the Manufacture phase.  An error message indicating “Quality Label Error,” would have appeared with a warning to alert the user.  The error message may be overridden, but the job will not transfer to the integrated furnace in this case.  It is not possible to recall the job.  Re-milling a new block will be required.

With gloved hands, carefully separate the restoration from the mandrel with a pointed bur.  Take precaution from dropping the restoration on a hard surface.  It is highly discouraged to tap the block as this may create fractures in the fragile green-state zirconia. 

KATANA™ Zirconia Sintering

(Please refer to the Owners Manual for additional information regarding the CEREC components)

KATANA™ Zirconia must be sintered in an furnace that is capable of reaching sintering temperatures.  KATANA™ Zirconia is validated in DentsplySirona integrated Speedfire oven for sintering.  An optional suction unit makes dry milling possible. It is possible to mill this product using wet milling with clean cooling water but tank cleaning and filter changing are necessary before using if you change to zirconia milling from another material. Furthermore, because the drying process is necessary, the sintering time becomes 43 minutes.

The restoration is milled in the ‘green’ state in order to allow milling in its softer state.  The restoration will shrink approximately 20-25% and transform into its proper shade once the sintering process is complete.

The sintering time is influenced by the temperature in the furnace. When the temperature in the furnace is higher than the default starting temperature, some time for cooling is necessary, thereby increasing the total time.

If you notice that restorations are suddenly looking more opaque upon sintering, or if there are consistent problems with fit, calibration of the furnace may be needed.  The calibration tool is designed for the fine adjustment of the temperature measurement and is only necessary when the thermo-element in the field has to be changed.  Please call your distributor technical support for assistance.

You may apply the same sintering parameters as KATANA™ Zirconia STML Disk for lab-use for any furnace that can be programmed for sintering materials.

The proper KATANA™ Zirconia block size was not chosen in the Manufacture phase.  An error message indicating “Quality Label Error,” would have appeared with a warning to alert the user.  The error message may be overridden, but the job will not transfer to the integrated furnace in this case.  It is not possible to recall the job.  Re-milling a new block will be required.

No.  The sintering process is an important factor in influencing translucency and strength.  The KATANA™ Zirconia block is uniquely manufactured, and has specific parameters to sinter.

For all shades the same program is utilized.  The sinter time is determined by the thickness of the restoration and whether it was wet or dry milled.  Generally, the sintering process takes 18mins for <6mm; 30mins for >6mm.

Sintering time is influenced by the temperature in the furnace. When the temperature in the furnace is higher than the default starting temperature, some time for cooling is necessary, thereby increasing the total time.

Depending on the wet or dry conditions of the milling process, the Speedfire LCD will automatically select a sintering program with/without pre-drying.  If any moisture is introduced to the material, you must select “Pre-drying and sintering”

Moisture was likely introduced and the restoration was not thoroughly dried prior to the sintering process.  Another possibility is that the cooling process was rushed.  Please follow the instructions on the SpeedFire LCD screen directing when to place the restoration on the cooling fan before it is ready for safe handling.

It is recommended to put the occlusal surface face down to set crown in as stable a position as possible during sintering. In the case of a small molar or anterior crown, it is recommended to put the lingual surface down.  Do not use pins, posts, stains/glazes, or refractory pastes during this process.

KATANA™ Zirconia Finishing

Once the restoration has completely cooled, you may conduct a try-in.  If necessary, make any occlusal adjustment by using a diamond bur or silicone points containing diamond particles. Use a copious spray of water or work on the prosthesis while it is wet. Be careful not to apply undue force, since this may cause a fracture, breakage or micro-cracks from local spot heating.  Polishing the restoration to smooth surfaces that come in contact with the opposing dentition.  Application of glaze is optional, but an additional glaze cycle in the furnace will be necessary with this option.

After occlusal adjustment, polish the opposing areas using a silicone point containing diamond particles and a polishing paste containing the same (ex. Pearl Surface Z), followed by glazing.

Polish the entire restoration with silicone points/wheels containing diamond particles, starting from coarse and ending with extra fine. Afterwards, use a zirconia polishing material (Pearl Surface Z, etc.), then brush or buff the restoration.

After using silicone points/wheels containing diamond particles, we suggest a polishing paste containing diamond particles, Pearl Surface Z, by Kuraray Noritake Dental.

No.  Kuraray Noritake’s unique pigment technology for zirconia and multi-layering lets the user fabricate zirconia restorations with natural color gradation and translucency close to those of natural teeth.  As a result, you do not need to add additional steps to your workflow.

Yes, it possible to perform color adjustment and characterization with CZR FC Paste Stain, by Kuraray Noritake Dental.

Yes, a polished restoration may look half a shade darker because of the way the light refracts off the surface of the smoothed material.

We recommend CZR FC Paste Stain which has been formulated for KATANA™ Zirconia.  We do not have any data regarding the use of competitors’ glaze materials.
The material itself doesn’t have fluorescence, but it is possible to add fluorescence onto the restoration with CZR FC Paste Stain. When you expect stronger fluorescence, please use Fluoro from FC paste Stain.

The glaze cycle for the Speedfire oven is 8:40.

The Speefire glaze cycle time is influenced by the temperature in the furnace from a previous job. When the temperature in the furnace is higher than the default starting temperature, time for cooling is necessary, thereby increasing the total time.

Apply sandblasting with gentle pressure (2 bar with 50 micron alumina) to create surface texture.  Clean the restoration.  Secure the restoration on a peg with refractory paste.  Apply CZR FC Paste Stain and Glaze. Choose the Glaze cycle on the Speedfire.  You have up to 2 glaze cycles programmed in the Speedfire, if needed.

KATANA™ Zirconia Cementation

Clean the restoration, the prepped tooth, and prepare for cementation.

Clean the tooth with KATANA™ Cleaner for 10 seconds, then rinse.  When you use PANAVIA™ SA Cement Universal, no primer is necessary.
After sandblasting (30-50 micron alumina; 14-59 PSI), clean it with KATANA Cleaner for 10 seconds, then rinse; finally, apply PANAVIA™ SA Cement Universal to the intaglio of the restoration.
PANAVIA™ SA Cement Universal or PANAVIA™ V5, which both contain MDP.  No additional primer is necessary when using either of these cements.
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