One therapeutical alternative in the treatment of functional disorders is the use of printed oral splints. The mechanical properties of these materials are highly essential to their clinical effectiveness, and their performance may vary depending on factors such as cleaning, post-polymerization, or their orientation during construction. The objective of this in vitro investigation is to evaluate the effectiveness of the selected materials in terms of their biaxial flexural strength in relation to the criteria listed above. Splint materials were used in the printing of 720 discs. The printing process was carried out in different orientations in relation to the building platform. Either an automatic or manual cleaning process was performed on the samples. For post-polymerization, either an LED or Xenon light was utilized. A piston-on-three-ball test was used to measure the biaxial flexural strength (BFS) of the materials after they were stored in water for either 24 h or 60 days. The homogeneity of the data was controlled by employing the Levene method, and the differences between the groups were analyzed using the ANOVA and Bonferroni methods. After being stored for twenty-four hours, the mean BFS ranged anywhere from 79 MPa to 157 MPa. Following a period of sixty hours, the BFS exhibited a substantial drop and revealed values that ranged from 72 to 127 MPa. There was no significant difference that could be identified between the materials or between the various cleaning processes. The results of post-polymerization showed that the LED light produced higher means than the Xenon light did. In terms of position, the mean values varied greatly, with 0°’s mean value being 101 MPa, 45°’s mean value being 102 MPa, and 90°’s mean value being 115 MPa. The use of a build orientation of 90° and post-polymerization with LED light resulted in significantly increased biaxial flexural strength. According to this study, this design should be implemented in order to ensure that splint materials have the highest possible strength.

3D printing as an additive manufacturing method has proven to be of great interest for the computerized production of oral splints. Various parameters must be taken into consideration when assessing the durability of oral splints in a wet environment, such as the mouth. The aim of this in vitro study was to assess the wear behavior and water sorption of two 3D-printed splint materials depending on their building orientation and post-processing parameters. The parameters considered included the type of post-polymerization and the type of cleaning utilized after printing. The average wear depth was between −421.8 μm and −667.5 μm. A significant influence of the building orientation (p < 0.001) but not of the material (p = 0.810), cleaning (p = 0.933), or post-polymerization (p = 0.237) on wear was demonstrated. The water sorption ranged between 13.8 μg/mm³ and 30.3 μg/mm³, featuring a significant dependency on material and building orientation but not on cleaning (p = 0.826) or post-polymerization (p = 0.343). Material and fabrication methods should be carefully selected, because the type of material and building orientation affect the wear and water sorption of additively manufactured splint materials.

Printed oral splints are a therapeutic alternative in the treatment of functional disorders. Their mechanical properties are crucial to their clinical success and their performance can vary depending on cleaning, post-polymerization, or build orientation. This in vitro study aimed to compare the biaxial flexural strength of the chosen materials depending on the aforementioned parameters. 720 discs (n = 15 per group, 16 mm x 2 mm) were printed from splint materials. Printing was performed under 90°, 45°, or 0° orientation to the building platform with supporting structures. Specimens were either automatically or manually cleaned with isopropanol. Post-polymerization was performed with LED- or Xenon-light. Biaxial flexural strength (BFS) was determined with a piston-on-3-ball test after 24 hours or 60 days water storage (37°C). Test specimens were preloaded with 0.5 N and the load was applied by a piston of 1.6 mm in diameter at 1 mm/min crosshead speed. Statistics were performed by using descriptive statistics, ANOVA, and Levene-tests. Mean BFS after 24 hours of storage varied between 79 MPa and 157 MPa. After 60 hours the BFS significantly decreased and revealed values ranging from 72-127 MPa (mean24 113 MPa, mean60 97 MPa; p<0.001). No significant differences could be determined between the materials (p=0.103) or between the different cleaning procedures (p=0.321). Post-polymerization yielded higher means with LED- (P1: 115 MPa) than with Xenon-light (P2: 95 MPa; p<0.001). Regarding position, the mean values ranged from 101 MPa for 0°, 102 MPa for 45°, and 115 MPa for 90°, which was significantly different (p<0.001). Build orientation of 90° and post-polymerization with LED-light provided significantly higher biaxial flexural strength and should be used to guarantee optimal strength of splint materials. Aging decreased the biaxial flexural strength of the tested specimens.