Ask three labs what a crown costs them and you will get three answers, because most of them are counting the blank and forgetting everything else. The material price is the smallest part of the real number, and it is the worst basis for choosing a system.
What belongs in the cost per unit
- Material: blank or puck, plus burs and any colouring consumables.
- Machine time: milling, sintering, finishing, and the labour those hours represent.
- Furnace energy and depreciation: sintering is a capital and utility cost, not free.
- Rework: the remake rate is often the largest hidden cost in the whole calculation.
- Finishing consumables: polishing, glazing, stains, abrasives.
A like-for-like comparison
The three systems most often compared are zirconia, porcelain-fused-to-metal (PFM) and lithium disilicate. Each has a different profile, and the honest comparison depends on the indication and the lab’s own remake rate.
| Factor | Zirconia | PFM | Lithium disilicate |
|---|---|---|---|
| Material cost | Moderate | Low | High |
| Machine/lab steps | Fewer (CAD/CAM) | Many (wax, cast, layer) | Moderate |
| Process labour | Low | High | Moderate |
| Rework sensitivity | Low-moderate | Moderate | Moderate |
| Aesthetic ceiling | Good to very good | Good | Very good |
The remake rate is the swing factor
Run the numbers with a 2% remake rate and again with an 8% rate. In most labs the difference between systems is small compared with the difference the remake rate makes. That means the highest-value investment is not a cheaper blank — it is reducing remakes, through validated sintering cycles, correct die spacer settings and consistent scanning. Our notes on margins and cement space are a good place to start.
How to build your own number
- Track every case for one month: material, machine minutes, labour minutes, consumables.
- Log remakes separately and attribute a cause to each.
- Divide the combined cost by the number of accepted units, not the number attempted.
- Compare systems on accepted units. That is the only figure your accountant and your customer both care about.
- Re-run quarterly. Material prices and remake rates both drift.
Frequently asked questions
Is the cheapest blank ever the right choice?
Only if the specification is genuinely equivalent and the remake rate does not move. In practice, inconsistent blanks raise remakes, and the saving disappears.
Should I compare on price per gram?
No. Yield per blank, nesting efficiency and remake rate matter more than the headline figure. Ask for a costed case study rather than a price list.
We will build a cost-per-unit estimate with you using your own case mix and remake rate. Send us your monthly volume and the systems you currently use and we will reply within 24 hours. See Resources for the comparison sheets.
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