Bonding Orthodontic Attachments to 3D-Printed Photosensitive Definitive Resin: An In Vitro Study

Background/Objectives: The increasing clinical integration of 3D-printed definitive resins requires a comprehensive understanding of their physicochemical properties and adhesive behavior. However, there is limited evidence regarding the optimal surface treatment and bonding strategies for clear aligner composite attachments on these materials. This study aimed to characterize a 3D-printed definitive resin, evaluate the effects of surface treatments on its surface topography, and compare the shear bond strength (SBS) of the bonded attachments using different adhesive systems, both before and after thermocycling. Methods: A total of 120 rectangular specimens were fabricated from a 3D printed dental resin (Crowntec^®, SAREMCO Dental AG-Mexico City, Mexico). For physicochemical characterization, six samples underwent scanning electron microscopy/energy-dispersive spectroscopy, X-ray diffraction, and thermogravimetric analysis. To evaluate surface topography, 42 polished specimens were assigned to three groups: untreated (control), etched with 4% hydrofluoric acid (HFA), or sandblasted with 50 µm Al₂O₃ (AA). Each group was subdivided for SEM observation and surface roughness (Ra) measurement. For SBS testing, 72 additional samples received the same surface treatments and were further subdivided according to the adhesive system: Transbond™ XT Primer (TXT) or Single Bond Universal (SBU). Results: The AA group showed the highest Ra (2.21 ± 0.30 µm), followed by HFA (0.81 ± 0.20 µm) and control (0.07 ± 0.30 µm) (p < 0.001). The highest SBS was observed in the AA + SBU group, followed by AA + TXT. Conclusions: Sandblasting with Al₂O₃ particles, combined with a universal adhesive, significantly improved bond strength, suggesting a viable protocol for 3D printed definitive composites in aligner attachment applications.