Analysis of the microstructural and mechanical properties of 3D-printed removable partial denture base materials

Background: Recent advancements in three-dimensional (3D) printing have introduced novel materials for removable partial dentures (RPD) base fabrication, promising improved mechanical properties, and biocompatibility. Materials and Methods: In this study, three different RPD base materials were evaluated: conventional heat-cured acrylic resin (Control), biocompatible 3D-printed resin (Test Group A), and a novel nanocomposite 3D-printed resin (Test Group B). A total of 30 standardized RPD base specimens (n = 10 per group) were fabricated according to established protocols. Microstructural analysis was performed using scanning electron microscopy (SEM), and the mechanical properties, including flexural strength and modulus, were determined using a universal testing machine. Results: Microstructural analysis revealed distinct differences among the materials. SEM images showed a well-defined and homogeneous microstructure in Test Group B, while Test Group A exhibited fewer voids compared to the Control group. Mechanical testing results indicated that Test Group B had the highest flexural strength (120 ± 5 MPa), followed by Test Group A (90 ± 4 MPa), and the Control group (75 ± 3 MPa). Similarly, Test Group B demonstrated the highest flexural modulus (3.5 ± 0.2 GPa), followed by Test Group A (2.8 ± 0.1 GPa), and the Control group (2.1 ± 0.1 GPa). Conclusion: These findings suggest that 3D-printed RPD base materials, particularly nanocomposite resins, hold promise for improving the overall quality and durability of removable partial dentures.