Thermoplastic resin fiber composites have an easy fabrication process, good mechanical properties, and compatible stiffness to tooth dentin. However, they have not yet attracted much interest in the field of dentistry. The current study was carried out to test a new proposed approach to manufacture a fiber reinforced composite endodontic post and evaluate its flexural strength through a two-point inclined loading test. The proposed fiber post manufacture approach depends upon a braiding technique of the glass fibers’ (GF) reinforcing component with thermoplastic polypropylene (PP) resin fibers that will later represent the resin matrix after thermal melting. Posts were made of different core (70%) and sheath (30%) construction (PP/GF ratios) using three different GF types and seizing pre-treatment to both fiber types. Two-point inclined loading test at 45 °C applied force angle was used to test the posts’ flexural strength. Fiber posts (1.6 mm in diameter) with pure GF (de-sized starch E-GF and pre-silanized S-GF) core, and sheath construction with higher PP/GF ratios, showed the significantly highest two-point bending strength (56.67 ± 4.89 and 53.96 ± 1.81 MPa, respectively), among experimental posts groups (except for the commercial control posts). However, posts with PP core type showed the lowest values (21.59 ± 1.86 and 16.54 ± 1.94 MPa for de-sized and E-glass sheath fibers, respectively). Based on these findings, the proposed approach was reliable in producing fiber-reinforced composite post with the desired dimensions and fiber distribution. Post construction with a pure GF core and higher PP/GF ratio showed considerably higher flexural strength and GF volume fraction comparable to commercial available post types.

Mechanical compatibility with the human dentin is a considerable issue when fabricating dental fiber posts. To this purpose, this study introduces a new method of fabricating compatible dental posts using braiding techniques of thermoplastic fibers (matrix) with glass fibers (reinforcement). Fifty fiber-reinforced composite (FRC) posts of thermoplastic yarns polypropylene (PP) braided with continuous filaments glass fibers (GFs) for reinforcement, varying in fiber volume fraction (FVF), and core types are fabricated and tested. Posts are performed using a braiding machine, and braids are placed in an aluminum mold. The filled mold is playced inside an oven at the melting temperature of the polypropylene to produce the final post’s shape. An ultrasonic test is conducted to measure the shear modulus and Young’s modulus of FRC post specimens by measuring the velocities of both the P-wave and S-wave. In order to ensure the accuracy of the measurements, each sample is measured three times, and then the means and standard deviations of each sample are calculated before analyzing the test results using the means of two steps, namely, clustering and comparing the P and R² values of each cluster, which revealed that FVF, fiber mass, and core type of the specimen had a significant effect on the resulted Young’s and shear modulus. The results indicate that the proposed method can fabricate competitive dental posts with regard to different fabricating variables. The samples show Young’s modulus ranges of from 10.08 GPa to 31.83 GPa. The following tested hypothesis is supported: the braiding technique of thermoplastic fibers with glass fibers will improve the mechanical compatibility of the resulting posts (ex vivo).

Braiding technology has been introduced to the composites industry in a spectrum of applications. Braiding configuration is defined by monitoring its variables according to the intended final usage which is the dental fiber posts in this study. Fiber post is a small rod used to support the teeth that have short clinical crown in the definitive restoration. Fiber posts are accepted widely because of their enhanced aesthetic and mechanical properties which enrich the dental field. Braided composite’s manufacturing process used to be achieved by passing the braided perform through the resin emulations, but in this paper a novel procedure is followed to fabricate the posts through two consecutive processes; first is the braiding process while the second is the melting process. Three different thermoplastic types; Polypropylene (PP), Polyester (PET), and Polyamide (PA) have been braided with the glass-fibers (GF), then the thermoplastic part of the braided perform has been melted to achieve the composite posts. The posts were assessed visually and mechanically, PP posts show the best performance visually and mechanically while PET posts show the least values in the mechanical testing and the most brittle forms in the visual assessment. Moreover, the PA posts show better mechanical values than the PET, but and the least homogenous forms in the visual assessment. The PET and PA posts brittleness could be attributed to the fabrication method used in this current approach which could have caused an accumulation of humidity because of less applied pressure on the mold during the melting process