Why Dental Diamond Burs Break Mid-Procedure – Causes, Risks & How to Prevent It
Dental diamond burs are essential rotary instruments used for
cutting, shaping, and finishing in restorative and surgical procedures. While
they are designed for durability and high-speed use, many dentists have
experienced a diamond bur snapping or breaking mid-procedure — an event
that can interrupt workflow, risk patient safety, and increase costs.
In this blog, we’ll explore why dental diamond burs break
during procedures, what underlying issues contribute to this failure, and how
dentists can prevent it with better practices and awareness.
๐งจ Why Do
Diamond Burs Break?
๐น 1. Improper
Bur Insertion (Not Fully Locked In)
One of the most common mistakes is not fully inserting and
locking the bur into the handpiece. This leads to:
- Bur
wobbling during rotation
- Increased
vibrations and torque imbalance
- Higher
chance of mechanical failure or ejection
๐ก Always
insert the bur until it fully clicks into place and gently test its security
before use.
๐น 2. Using
the Wrong Bur Length for the Handpiece
Using standard or long shank burs in mini head or pediatric
handpieces causes overextension. This adds strain and often results in:
- Flexing
of the bur shaft
- Premature
snapping or bending
- Damage
to turbine bearings
๐ก Use
short shank burs in small-head handpieces to maintain stability.
๐น 3. Excessive
Pressure While Cutting
Applying too much force instead of letting the bur do the work
can:
- Stress
the bur shaft
- Strip
the diamond grit layer
- Heat
up the bur, weakening its structure
- Lead
to fracture or snapping, especially in fine or extra-fine burs
๐ก Use a
feather-light touch and let the bur’s design do the cutting.
๐น 4. Using
Worn-Out or Damaged Burs
Burs wear out over time, and using a dull or cracked bur
increases the risk of:
- Unexpected
snapping during rotation
- Poor
cutting performance and more force application
- Damage
to the handpiece
๐ก Visually
inspect burs before use. Discard ones that show wear, corrosion, or imbalance.
๐น 5. Heat
Buildup Due to Poor Cooling
Inadequate water spray can cause friction and overheating,
which:
- Weakens
the metal core of the bur
- May
lead to thermal expansion and fracture
- Can
also damage surrounding tooth or pulp tissue
๐ก Ensure
your air-water coolant spray is functional and well-aligned with the bur.
๐น 6. Inferior
Quality or Fake Burs
Cheaper, low-quality burs or counterfeit products:
- May
use substandard bonding techniques
- Have
poor diamond grit adhesion
- Are
more prone to failure, flaking, and shaft breakage
๐ก Always
source burs from trusted, reputed suppliers to ensure quality and safety.
⚠️ What
Happens When a Bur Breaks Mid-Procedure?
- Sudden
halt of procedure flow and operator stress
- Potential
injury or trauma to soft tissues or tongue
- Patient
anxiety and loss of trust
- Bur
tip embedded in tooth or cavity space requiring retrieval
- Possible
damage to the turbine mechanism
✅ How to
Prevent Bur Breakage
✔️ Use the
correct bur type, shape, and length for the intended procedure
✔️ Lock burs completely and
double-check before starting
✔️ Apply light pressure and let the
bur work
✔️ Maintain adequate cooling spray
✔️ Replace burs regularly – don't
wait for them to break
✔️ Invest in quality over
quantity
๐ Conclusion
While diamond burs are built for strength and speed, they are not indestructible. Most mid-procedure breakages are preventable with the right bur-handpiece pairing, good technique, and regular inspection. By staying vigilant, dentists can ensure smoother procedures, safer patient experiences, and longer-lasting equipment.