Effect of layer thickness, build angle, and viscosity on the mechanical properties and manufacturing trueness of denture base resin for digital light processing

Abstract

ObjectivesTo investigate effects of layer thickness, build angle, and viscosity on the mechanical properties and trueness of denture base resins used for digital light processing (DLP). MethodsTwo denture base resins for DLP in different viscosity (high and low) were tested by using two manufacturing parameters:1) layer thickness (LT) (50- or 100-μm) and 2) build angle (BA) (0-, 45-, and 90-degree). disk- and bar-shaped specimens were used to evaluate hardness and flexural strength, respectively. Denture base specimens were used to examine trueness, and the deviation was calculated as the root mean square. Three-way analysis of variance (ANOVA) was conducted to determine the interaction among the three factors (viscosity, LT, and BA). Statistical significance was set at P < .05. ResultsEffects of LT and BA on hardness differed according to viscosity, with significant interactions among three factors (P=.027). Regardless of LT or BA, the low-viscosity group had higher hardness than the high-viscosity group (P<.001). In terms of flexural strength, no significant interaction was detected between the factors (P=.212), however, the effects of LT and BA were significant (P=.003 and P<.001, respectively). Regarding trueness, a significant interaction was observed between viscosity and BA (P=.001). Low-viscosity group had higher trueness than high-viscosity group when the 45- and 90-degree BA were applied (P<.001). ConclusionsLT and BA significantly affected the mechanical properties and trueness of the 3DP denture base, depending on the viscosity. For hardness and trueness, using low-viscosity resin and manufacturing with 50-μm LT and 45-degree BA are recommended. Clinical SignificanceResin viscosity affects the influence of LT and BA on the hardness, flexural strength, and trueness of DLP-generated denture bases. A 50-μm LT and 45-degree BA can be used with a low-viscosity resin to fabricate denture bases with higher hardness and trueness.