Objectives: The objective of this study was to investigate the mechanical properties of high-impact (HI) heat-cured acrylic resin (PMMA) reinforced with silane-treated zirconia nanoparticles. Methods: Forty-five PMMA specimens reinforced with zirconia were fabricated and divided into three groups: Pure HI PMMA (control group), PMMA reinforced with 3 wt.% of non-silanised zirconia nanoparticles and PMMA reinforced with 3 wt.% of silanised zirconia nanoparticles. Silanised and non-silanised zirconia nanoparticles were analysed with Fourier Transform Infrared (FTIR) Spectroscopy. For measuring the flexural modulus and strength, a Zwick universal tester was used, and for surface hardness, a Vickers hardness tester were used. Furthermore, raw materials and fractured surfaces were analysed using Scanning Electron Microscopy (SEM). A one-way ANOVA test followed by a post-hoc Bonferroni test was employed to analyse the data. Results: The results showed that the mean values for flexural strength (83.5 ± 6.2 MPa) and surface hardness (20.1 ± 2.3 kg/mm²) of the group containing 3 wt.% treated zirconia increased significantly (p < 0.05) in comparison to the specimens in the group containing non-treated zirconia (59.9 ± 7.1 MPa; 15.0 ± 0.2 kg/mm²) and the control group (72.4 ± 8.6 MPa; 17.1 ± 0.9 kg/mm²). However, the group with silanised zirconia showed an increase in flexural modulus (2313 ± 161 MPa) but was not significantly different (p > 0.05) from the non-silanised group (2207 ± 252 MPa) and the control group (1971 ± 235 MPa). Conclusion: Silane-treated zirconia nano-filler improves the surface hardness and flexural strength of HI PMMA-zirconia nanocomposites, giving a potentially longer service life of the denture base.

When PMMA denture base acrylics are exposed to oral environments for prolonged periods, the denture base absorbs water, which has a negative influence on the denture material and the degree to which the denture base will be clinically effective. This study assessed the water sorption, desorption, and hygroscopic expansion processes within PMMA denture-base resins reinforced with nanoparticles or fibre in comparison to the non-reinforced PMMA. The surfaces of the fillers were modified using a silane coupling agent (y-MPS) before mixing with PMMA. Group C consisted of specimens of pure PMMA whereas groups Z, T, and E consisted of PMMA specimens reinforced with ZrO₂, TiO₂ nanoparticles, or E-glass fibre, respectively. The reinforced groups were subdivided into four subgroups according to the percentage filler added to the PMMA resin by weight (1.5%, 3.0%, 5.0%, or 7.0%). Five specimens in disc shape (25 ± 1 mm × 2.0 ± 0.2 mm) were tested for each group. To assess water sorption and hygroscopic expansion, specimens from each group were individually immersed in water at 37 ± 1 °C for 180 days. The samples were then desorbed for 28 days at 37 ± 1 °C, to measure solubility. Water sorption and solubility were calculated using an electronic balance in accordance with ISO Standard 20795-1, and hygroscopic expansion was measured using a laser micrometre. Statistical analysis was undertaken at a p ≤ 0.05 significance level using a one-way ANOVA followed by Tukey post-hoc tests. The results demonstrated that the values of sorption (W_sp), mass sorption (M_s%), and % expansion within the tested groups reached equilibrium within 180 days. A noticeable difference was observed in groups Z and E for (W_sp)/(M_s%) compared to the Group C, but this was not significant. However, the difference between Group C and Group T for these measurements was significant. Non-significant differences also existed between each respective reinforced group and the control group in terms of hygroscopic expansion % values. During the 28-day desorption period, there were no differences in the values of solubility (W_sl)/mass desorption (M_d%) between Group C and each of the reinforced tested groups. The findings indicate that the inclusion of ZrO₂ nanoparticles or E-glass fibres does not increase the water solubility/sorption of the PMMA. However, modifying the PMMA with TiO₂ did significantly increase the water sorption level.

Artificial biomaterials are being developed for use in denture base with symmetrical properties to restore the aesthetics and functionalities. The rough surface of denture base resin promotes the adhesion of microorganisms and plaque accumulation. This study aimed to explore the consequences of polishing times on the surface roughness of high-impact (HI) heat-polymerized PMMA denture base acrylic resin reinforced with zirconia nanoparticles (nanocomposite). Thirty specimens (25 ± 0.50 mm in diameter and 2 ± 0.10 mm thickness) were fabricated from HI PMMA by adding zirconia nanoparticles at different concentrations of (0 wt.%, 1.5 wt.%, 3 wt.%, 5 wt.%, 7 wt.%, and 10 wt.%). Specimens were divided into six groups (n = 5) and surface roughness (Ra) was measured before and after polishing with a standard protocol for one and two minutes. The addition of zirconia in PMMA at low concentrations (1.5 wt.%, 3 wt.%, and 5 wt.%) did not negatively affect the surface finish of the denture base composites following conventional polishing and remained below the clinically acceptable limit (0.2 µm). After one minute of polishing, only the 10 wt.% zirconia (0.17 ± 0.03 µm) demonstrated a substantial rise in median surface roughness, in comparison with the control group (0.11 ± 0.01 µm). It is concluded that the group containing 3 wt.% (0.10 ± 0.01 µm) of zirconia is the optimum concentration to obtain the best symmetrical surface finish after two minutes of polishing.