Purpose To explore fracture strength and failure behaviour of minimally invasive CAD-CAM composite resin overlay restorations.

Methods Eighty bi- and tri-layer cylindrical overlay model including the restoration bonded over bovine tooth dentin (Groups D) and enamel-dentin (Groups E) were assembled (diameter 9 mm). Restorations were milled from CAD-CAM composite resin blocks (Brilliant Crios, Coltène/Whaledent AG) in different thicknesses (0.5mm, 1mm, 1.5mm, 2mm) and equally distributed in four Groups D and four Groups E (n=10). All specimens were submitted to an Hertzian load-to-failure contact test with spherical indenter. Critical loads were recorded in Newton and data were analysed using Kruskal–Wallis test for multiple and Mann-Whitney test for 2-samples comparisons (p < 0.05). Fragments were examined using SEM. The stress distribution for specimens with restorations of 0.5 mm and 2 mm was also investigated with FEA.

Results For all specimens, the mean static loads in Newton increased with an increase in restoration thickness. On contrary, restorations with the same thickness displayed higher resistance values when bonded over enamel than dentin, except for the 2-mm thick restorations. A damage competition was detected between cone/median cracks originating at the loading contact area of the restorations and radial cracks beginning at their inner surface, with the former prevailing in restorations bonded on enamel and the latter being dominant for restorations bonded on dentin.

Conclusions For bonded ultra-thin resin composite restorations (0.5 mm to 1.5 mm) enamel as bonding substrate assures higher critical loads to fracture than dentin. This influence gradually decreases as restoration thickened.