Development of 3-dimensionally printed denture base material utilizing hybrid polymer: A preliminary investigation.

Statement of problem: Current 3-dimensionally (3D) printed denture bases have inadequate strength and durability for long-term use, and milled denture bases generate excessive waste. Addressing these limitations is crucial to advancing prosthetic dentistry, ensuring improved patient outcomes and promoting environmental responsibility.

Purpose: The purpose of this in vitro study was to incorporate microparticles into a commercially available 3D printed denture base resin and compare its mechanical and biological properties with the conventional polymethyl methacrylate (PMMA) denture base material.

Material and methods: Microparticles were collected from milled zirconia blanks and were blended with a 3D printing denture base resin (NextDent Denture 3D+). The optimal zirconia microparticle content (2%) for blending and printed was determined by using a liquid-crystal display (LCD) 3D printer. The printed specimens were then postrinsed and postpolymerized based on the manufacturer's instructions. Mechanical and biological characterization were carried out in terms of flexural strength, fracture toughness, and fungal adhesion. One-way ANOVA was carried out to analyze the results statistically.

Results: The incorporation of microparticles in the 3D printed denture demonstrated higher mechanical strength (104.77 ±7.60 MPa) compared with conventional heat-polymerized denture base resin (75.15 ±24.41 MPa) (P<.001), but the mechanical strength deteriorated when compared with the unmodified 3D printing resin (122.17 ±11.58 MPa) (P<.001). However, the modified 3D printed denture showed greater antibacterial activity (1184.00 ±243.25 CFU/mL) than the unmodified resin (1486.50 ±103.94 CFU/mL) (P=.045).

Conclusions: The incorporation of microparticles into the 3D printed denture base resin demonstrated the potential to enhance the mechanical and biological properties of the denture base when compared with conventional techniques. However, when compared with the unmodified 3D printed denture base resin, the mechanical properties deteriorated while the biological properties improved.