Incorporation of Bioactive Glass Nanoparticles in 3D-Printed Acrylic Resin: Impact on Mechanical and Physical Properties: An In Vitro Study

Objective: This study aimed to evaluate the effect of incorporating bioactive glass (BAG) nanoparticles at varying concentrations on the mechanical and physical properties of 3D-printed denture base resin. Specifically, flexural strength, surface roughness, and surface hardness. Methods: Six groups of 3D-printed acrylic resin specimens were studied: one control group (0% BAG) and five experimental groups containing 1%, 1.5%, 2%, 2.5%, and 3% BAG nanoparticles by weight. Flexural strength, surface hardness, and roughness testing were done on 10 specimens. All were digitally planned and 3D printed using SprintRay. XRD, FTIR-ATR, and FESEM were used to characterise the sample. Mechanical testing includes three-point bending for flexural strength, Shore D durometers for surface hardness, and portable roughness testers for surface roughness. Results: Flexural strength did not differ significantly among groups (ANOVA, p = 0.527), with mean values ranging from 130.6 ± 2.4 MPa (control) to 135.5 ± 2.0 MPa (3% BAG). Surface hardness showed significant improvements at 1.5% (89.9 ± 1.2) and 2% (89.9 ± 1.2) compared with the control (88.2 ± 1.6; p = 0.028 and p = 0.020, respectively). Surface roughness decreased progressively with BAG addition, and the 3% group (0.063 ± 0.017 μm) was significantly smoother than both the control (0.134 ± 0.090 μm; p = 0.01) and the 1% group (0.125 ± 0.101 μm; p = 0.014). Conclusions: Incorporating up to 3% BAG nanoparticles into 3D-printed denture base resin can improve surface properties without compromising flexural strength. The concentration between 1.5% and 3% significantly increased the surface hardness and roughness. These advancements imply that BAG-modified resins have the potential to provide advantages such as enhanced clinical longevity and ease of use for prosthetic devices that are manufactured using 3D technology.