Wear Resistance and Fracture Load of Ceramic-Reinforced Hybrid 3D-Printed Denture Teeth: A Comparative Analysis Before and After Thermal Aging

Abstract

Background/Objectives: This in vitro study evaluated the wear resistance and fracture load of newly introduced ceramic-reinforced hybrid 3D-printed permanent resin tooth materials and compared their mechanical performance with prefabricated polymethylmethacrylate denture teeth and a conventional 3D-printed resin tooth material. Methods: Mandibular first molars were digitally scanned in an anatomic form for fracture load testing and a flattened occlusal form for wear depth evaluation. Four 3D-printed materials were fabricated: one conventional 3D-printed resin (NextDent C&B MFH) and three ceramic-reinforced hybrid resins (VarseoSmile, Crowntec, and Flexcera Smile). Half the specimens underwent thermal cycling (10,000 cycles). Wear testing was performed in a chewing simulator using a ceramic antagonist under 49 N for 120,000 cycles. Wear depth (µm) was quantified with 3D deviation analysis using Geomagic software. Fracture load was measured using a universal testing machine. Data were analyzed using two-way ANOVA and Tukey post hoc comparisons (α = 0.05). Results: Ceramic-reinforced hybrid materials exhibited significantly lower wear depth and higher fracture load values than prefabricated polymethylmethacrylate and conventional 3D-printed resin tooth materials before and after thermal cycling (p < 0.001). Conventional 3D-printed resin tooth materials consistently showed the greatest wear depth and lowest fracture load. Thermal cycling significantly reduced mechanical performance in all groups. Conclusions: Under the present in vitro conditions, ceramic-reinforced hybrid 3D-printed resin tooth materials demonstrated superior wear behavior and fracture resistance to prefabricated and conventional 3D-printed resin tooth materials.