Manufacturing of leucite glass-ceramics often leads to materials with inhomogeneous microstructures. Crystal-glass thermal mismatches which produce microcracking around larger crystals-agglomerates are associated with reduced mechanical properties. The hypotheses were that fine (< 1 µm) crystal size and uniform microstructure in a thermally matched glass would increase the biaxial flexural strength (BFS). Glass was synthesized, attritor-milled, and heat-treated. Glasses and glass-ceramics were characterized by XRD, SEM, and Dilatometry. Experimental (A, M1A and M2A) and commercial glass-ceramics were tested by the BFS test. Experimental glass-ceramics showed an increased leucite crystal number and decreased crystal size with glass particle size reduction. Leucite glass-ceramics (< 1 µm) showed minimal matrix microcracking and BFS values of [mean (SD) MPa]: M1A = 253.8 (53.3); and M2A = 219.5 (54.1). Glass-ceramics M1A and M2A had higher mean BFS and characteristic strength than the IPS Empress Esthetic glass-ceramic (p < 0.05). Fine-grained, translucent leucite glass-ceramics were synthesized and produced high mean BFS.
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