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Effect of Thermal Processing on Surface Roughness of Injection-Molded Denture Base Polymers
Bozhana Chuchulska1, Mariya Dimitrova1, Boyan Dochev2,3
1Department of Prosthetic Dentistry, Faculty of Dental Medicine, Medical University of Plovdiv, 4000 Plovdiv, Bulgaria.
Polymers
|May 13, 2026
Summary
Higher extrusion temperatures for ThermoSens denture material improve mechanical strength but may increase surface roughness. Optimal processing balances these factors for better clinical performance and longevity.
Area of Science:
- Materials Science
- Biomaterials Engineering
- Polymer Science
Background:
- Surface roughness and mechanical properties are crucial for denture base material performance, influencing clinical behavior, hygiene, and longevity.
- ThermoSens is a thermoplastic polymer used in denture bases, and its processing conditions can significantly impact its final properties.
Purpose of the Study:
- To investigate the effect of two extrusion temperatures (280°C and 300°C) on the surface roughness and compressive strength of ThermoSens specimens.
- To evaluate the changes in surface roughness and compressive strength over a 7-day immersion period.
Main Methods:
- Specimens were processed at 280°C and 300°C.
- Surface roughness was measured using a contact profilometer at baseline, 24 hours, and 7 days.
- Compressive strength was determined after 7 days according to ISO 604 guidelines.
Main Results:
- Specimens processed at 300°C showed a greater percentage reduction in surface roughness (28.3%) compared to 280°C (18.3%), but maintained higher absolute roughness values.
- The 300°C group exhibited significantly higher compressive strength (91.6 MPa) and modulus (1887.9 MPa) than the 280°C group (82.3 MPa; 1755.4 MPa).
Conclusions:
- A trade-off exists between enhanced mechanical properties at higher extrusion temperatures and reduced surface roughness at lower temperatures for ThermoSens.
- Careful optimization of extrusion processing conditions is necessary to balance surface characteristics and mechanical performance for improved denture base materials.
