Polymer-infiltrated zirconia-ceramic composite (PIZC) comprises a pre-sintered zirconia-ceramic matrix and a polymer. In this work, pre-sintered zirconia-ceramic was infiltrated with varied amounts of methacrylate-based polymer. Therefore, this paper reports the effect of polymer amount on the mechanical behavior of PIZC at 1100–1300 ⁰C pre-sintering temperatures. Conventional mechanical tests were performed to obtain the elastic modulus and fracture toughness while Vickers micro-indentations were employed to extract the Vickers hardness. Advanced mechanical behaviour analysis was characterized by plastic deformation resistance, elastic and plastic deformation components and brittle index. Increasing the amount of polymer from 0 to 42% led to the corresponding decrease in elastic modulus, hardness and fracture toughness by at least 78, 85 and 75%, respectively. As the temperature was increased, both elastic modulus and hardness increased while the fracture toughness initially increased but decreased at higher temperature. Mechanical properties and polymer amount were well modelled by connected-grain models which usefully explained the densification process occurring at higher temperatures. Plastic deformation resistance and component and brittleness index confirmed better plastic properties for PIZC at higher polymer amounts and lower temperature. Therefore, in order to utilize the plastic properties of PIZC during the CAD/CAM process, these findings recommended its processing at not-lower-than 26% polymer amount and 1100 ⁰C, which could greatly facilitate its precision ductile machining mode realization. Finally, the results provide a technical guidance for the selection of appropriate polymer amount when fabricating dental restorations from this novel ceramic-composite.

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