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Hala B Elzahar,1,2 Mohamed S El-Okaily,3 Mohamed H Khedr,2 Mohamed Amgad Kaddah,1 Ahmed AG El-Shahawy2 1Faculty of Dentistry-Cairo University, Department of Orthodontics, Cairo, Egypt; 2Materials Science and Nanotechnology Department, Faculty of Postgraduate Studies for Advanced Sciences (PSAS), Beni-Suef University, Beni-Suef, Egypt; 3Nanomedicine & Tissue Engineering Laboratory, Medical Research Center of Excellence (MRCE), Refractories, Ceramics & Building Materials Department (Biomaterials Group), National Research Centre, Cairo, EgyptCorrespondence: Ahmed AG El-Shahawy, Tel +20 1226798209, Email Ahmed.elshahawy@psas.bsu.edu.egBackground: Though acrylic resins possess many useful properties, denture fracture is nevertheless a familiar issue.Objective: This study aimed to determine the effect of low-percent recycled Zirconia nanoparticles as filler on the transverse strength, impact strength, surface hardness, water sorption, and solubility of resin using the sprinkle cold-curing technique.Materials and Methods: Various formulae were prepared and mixed with PMMA (polymer) powder containing varying percentages (0.01%, 0.1%, 0.3%, and 0.5%) of recycled ZrO2NPs to mono-methyl methacrylate (MMA monomer). A 2-hydroxyethyl-methacrylate (HEMA) agent was used to functionalize recycled zirconia (ZrO2) nano-fillers. X-ray diffraction, field emission scanning electron microscopy, high-resolution transmission electron microscopy, energy-dispersive X-ray spectroscopy, and dynamic light scattering were used to characterize the samples. For mechanical tests, standard metallic moulds (according to American Dental Association specification no. 27) were machined for 60 specimens’ preparation, 12 for each percent (zero, 0.01%, 0.1%, 0.3%, and 0.5%). A one-way ANOVA test was used to compare the five groups for parametric data, while the Kruskal–Wallis test was employed for nonparametric data. The P 0.05 value was accepted as the significance level. All formulae were tested for cytotoxicity at 24 and 48 hours on WI38 normal lung cell lines.Results: The XRD analysis demonstrated the tetragonal crystallographic structure of the recycled zirconia nanoparticles. Incorporating a low percentage of recycled ZrO2 nanoparticles (0.01%, 0.1%, 0.3%, and 0.5%) improved the tested properties of PMMA to different degrees in a significant and non-significant pattern, while the optimal tested percent was 0.3%.Conclusion: The 0.3% percentage of recycled zirconia nanoparticles maintained and improved the physical and mechanical properties of acrylic resin. Recycled ZrO2/PMMA nanocomposite is a synergistic candidate due to its economic return and clinical application safety.Keywords: acrostone, cold cure, novel, recycled zirconia, sprinkle