Comparison of the Bonding Strength of Denture Base Materials Obtained by Different Manufacturing Methods to Reline Materials

The durability of bonding between the denture base and reline materials plays a critical role in the long-term success of removable prostheses. This study aimed to compare the bond strength of denture base resins fabricated by heat-polymerization, CAD-CAM milling, and 3D printing techniques after thermocycling and different surface treatments. A total of 216 specimens (10 × 10 × 20 mm) were prepared from three base materials and subjected to surface treatment via no treatment (control), alumina air abrasion, or an Er/YAG laser. Two reline materials (hard and soft) were applied according to manufacturers’ instructions. All samples underwent 5000 thermal cycles and were tested using a tensile bond strength test. SEM analysis was performed to evaluate failure modes. The highest bond strength was observed in the milled resin group combined with alumina air abrasion and the hard reline material, reaching up to 12.41 MPa. Statistically significant effects were found for the material type, surface treatment, and reline material (p < 0.001). The results indicate that material properties, surface preparation, and reline type critically influence bond performance. Milled PMMA bases and hard relining agents, particularly when combined with air abrasion, offer superior bonding outcomes.