This paper reviews acrylic denture base resin enhancement during the past few decades. Specific attention is given to the effect of fiber, filler, and nanofiller addition on poly(methyl methacrylate) (PMMA) properties. The review is based on scientific reviews, papers, and abstracts, as well as studies concerning the effect of additives, fibers, fillers, and reinforcement materials on PMMA, published between 1974 and 2016. Many studies have reported improvement of PMMA denture base material with the addition of fillers, fibers, nanofiller, and hybrid reinforcement. However, most of the studies were limited to in vitro investigations without bioactivity and clinical implications. Considering the findings of the review, there is no ideal denture base material, but the properties of PMMA could be improved with some modifications, especially with silanized nanoparticle addition and a hybrid reinforcement system.

Background: Repeated fracture of the denture base is a common problem in prosthodontics, and it represents a nuisance and a time sink for the clinician. Therefore, the possibility of increasing repair strength using new reinforcement materials is of great interest to prosthodontists. Aim of the study: This study aimed to evaluate the effects of incorporation of zirconia nanoparticles (nano-ZrO₂) on the flexural strength and impact strength of repaired polymethyl methacrylate (PMMA) denture bases. Materials and methods: One hundred eighty specimens of heat-polymerized acrylic resin were fabricated (90 for each test) and divided into three main groups: one control group (intact specimens) and two groups divided according to surface design (45° bevels and butt joints), in which specimens were prepared in pairs to create 2.5 mm gaps. Nano-ZrO₂ was added to repair resin in 2.5 wt%, 5 wt%, and 7.5 wt% concentrations of acrylic powder. A three-point bending test was used to measure flexural strength, and a Charpy-type test was used to measure impact strength. Scanning electron microscopy was used to analyze the fracture surfaces and nano-ZrO₂ distribution. The results were analyzed with a paired sample t-test and an unpaired t-test, with a P-value of ≤0.05 being significant. Results: Incorporation of nano-ZrO₂ into the repair resin significantly increased flexural strength (P<0.05). The highest value was found in the bevel group reinforced with 7.5% nano-ZrO₂^, whereas the lowest value was found in the butt group reinforced with 2.5% nano-ZrO₂. The impact strength values of all repaired groups were significantly lower than those of the control group (P<0.05). Among repaired groups, the higher impact strength value was seen in the butt group reinforced with 2.5% nano-ZrO₂. The bevel joint demonstrated mainly cohesive failure, whereas the butt joint demonstrated mainly adhesive failure. Conclusion: Incorporation of nano-ZrO₂ into the repair resin improved the flexural strength of repaired denture bases, whereas it decreased impact strength, especially with high nano-ZrO₂ concentrations.

Background: Polymethyl methacrylate (PMMA) is widely used for the fabrication of removable prostheses. Recently, zirconium oxide nanoparticles (nano-ZrO₂) have been added to improve some properties of PMMA, but their effect on the optical properties and tensile strength are neglected. Objective: The aim of this study was to investigate the effect of nano-ZrO₂ addition on the translucency and tensile strength of the PMMA denture base material. Materials and methods: Eighty specimens (40 dumbbell-shaped and 40 discs) were prepared out of heat-polymerized acrylic resin and divided into four groups per test (n=10). The control group for each test included unreinforced acrylic, while the test groups were reinforced with 2.5, 5, and 7.5 wt% nano-ZrO₂. Acrylic resin was mixed according to manufacturer’s instructions, packed, and processed by conventional method. After polymerization, all specimens were finished, polished, and stored in distilled water at 37°C for 48±2 hours. Tensile strength (MPa) was evaluated using the universal testing machine while the specimens’ translucency was examined using a spectrophotometer. Statistical analysis was carried out by SPSS using the paired sample t-test (p≤0.05). A scanning electron microscope was used to analyze the morphological changes and topography of the fractured surfaces. Results: This study showed that the mean tensile strength of the PMMA in the test groups of 2.5%NZ, 5%NZ, and 7.5%NZ was significantly higher than the control group. The tensile strength increased significantly after nano-ZrO₂ addition, and the maximum increase seen was in the 7.5%NZ group. The translucency values of the experimental groups were significantly lower than those of the control group. Within the reinforced groups, the 2.5%NZ group had significantly higher translucency values when compared to the 5%NZ and 7.5%NZ groups. Conclusion: The addition of nano-ZrO₂ increased the tensile strength of the denture base acrylic. The increase was directly proportional to the nano-ZrO₂ concentration. The translucency of the PMMA was reduced as the nano-ZrO₂ increased. Clinical significance: Based on the results of the current study, the tensile strength was improved with different percentages of nano-ZrO₂ additions. However, translucency was adversely affected. Therefore, it is important to determine the appropriate amount of reinforcing nano-ZrO₂ that will create a balance between achieved properties – mechanical and optical.

This study aimed to evaluate the water sorption, solubility, and translucency of 3D-printed denture base resins (NextDent, FormLabs, and Asiga), compare them to heat-polymerized acrylic denture base resins, and assess their performance under the effects of thermal cycling. A total of 80 acrylic disc specimens were used in the current study, categorized into four groups (n = 10); in one group, the samples were fabricated conventionally with a heat-polymerizing process (control), while the other three groups were fabricated digitally from different 3D-printed reins (NextDent, FormLabs, and Asiga). Specimens were fabricated according to the manufacturers’ recommendations and immersed in distilled water for 48 h at 37 °C. Data on water sorption, solubility, and translucency measurements (T1) were obtained. All the specimens were subjected to 5000 thermal cycles, and then the measures were repeated using the same method (T2). Data analysis was attained via ANOVA and the post hoc Tukey test (α = 0.05). The type of resin significantly affected the values of water sorption, solubility, and translucency (p < 0.001). The water sorption of 3D-printed resins was increased significantly in comparison to control with or without a thermal cycling effect. In terms of solubility, a significant increase in 3D-printed resins before thermocycling was observed; however, after thermocycling, Asiga had a significantly low value compared to the other groups (p < 0.001). Thermal cycling increased the water sorption and solubility of all tested materials. In comparison to control, the translucency of the 3D-printed resins was significantly decreased (p < 0.001). The translucency was significantly decreased per material in terms of the thermal cycling effect (before and after). NextDent showed significantly low translucency values (p < 0.001) compared to the other groups. All 3D-printed resin groups had higher water sorption and solubility and lower translucency values in comparison to the heat-polymerized resin group. Regardless of resin types, thermal cycling adversely affected all tested properties.