The Effect of 3D Printing Layer Thickness and Post-Polymerization Time on the Flexural Strength and Hardness of Denture Base Resins

Purpose: This study evaluates and compares the effect of printing layer thickness (LT) and post-polymerization time (PPT) on the flexural strength and hardness of three 3D-printed resins after thermal aging. Methods: A bar shape (64 × 10 × 3.3 mm) and a disc shape (15 × 2 mm) were designed for flexural strength and hardness testing, respectively. ASIGA, NextDent, and FormLabs 3D-printed resins were used to print specimens with different LTs (25 µm, 50 µm, and 100 µm). Each thickness group was post-polymerized (PP) for different times (15, 30, 60, and 90 min). All printed specimens were thermally cycled (5000 cycles) and then tested, measuring the flexural strength and hardness using a universal testing machine and Vickers hardness tester, respectively. The data were analyzed using ANOVA and a post hoc Tukey’s test (α = 0.05). Results: A PPT of 90 min showed the highest flexural strength. In comparisons of the LTs, 25 µm and 50 µm significantly increased flexural strength compared with 100 µm, which showed the lowest value for each PPT. The hardness increased as the PPT increased for all materials. In our LT comparison, 25 µm and 50 µm significantly increased the hardness for NextDent and FormLabs resins, while only 25 µm showed high hardness compared with 50 µm and 100 µm for ASIGA. Conclusion: Both parameters (LT and PPT) impact flexural strength and hardness. Increased PPT with the minimum LT is recommended.