Production of Green Synthesized Zinc Oxide Nanoparticle-Reinforced PMMA-Based Photopolymer Resins on DLP-Based 3D Printers and Characterization

In this study, the structural, thermal, and mechanical properties of nanocomposites obtained by adding zinc oxide (ZnO) nanoparticles (NPs), produced by phyto-mediated synthesis using Dianthus chinensis plant extract, to a PMMA-based photopolymer resin at different ratios (0.05%, 0.10%, 0.15%, 0.20%, and 0.25%, by weight) were evaluated. The prepared composite resins were produced in different test geometries using a DLP (digital light processing)-based 3D printer (Asiga Ultra). Following the structural characterization of ZnO nanoparticles, tensile, compressive, and flexural mechanical tests were performed on the resulting composites, as well as FTIR, TGA, DSC, and DMA analyses. The FTIR results showed that ZnO NPs were physically integrated into the matrix. TGA and DSC analyses revealed that the addition of ZnO NPs, particularly at an addition rate of 0.15%, increased thermal stability. DMA analyses showed an increase in storage modulus and glass transition temperature as the addition rate increased. In mechanical tests, the highest modulus of elasticity and maximum strength values were obtained at additive ratios of 0.10–0.15%. The highest tensile strength (55.31 MPa) and compressive strength (388.53 MPa) were obtained at ZnO contents of 0.10–0.15 wt%, while the maximum flexural strength reached 125.94 MPa at 0.15 wt% ZnO. In addition, the storage modulus increased from 1.469 × 109 Pa for the control resin to 1.872 × 109 Pa for the composite containing 0.15 wt% ZnO, indicating improved stiffness and thermomechanical stability. The stress–strain curves show that improvements in ductility and deformation capacity of the material are achieved at these additive ratios. The findings demonstrate that green-synthesized ZnO nanoparticles are an effective and sustainable additive material for improving the mechanical and thermal performance of DLP-based photopolymer dental resins.