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3D Printing of Block Copolymer-Based Fracture Tough Denture Base Materials
Kai Rist1, Iris Lamparth1, Sadini Omeragic1
1Ivoclar Vivadent AG, Bendererstrasse 2, FL-9494 Schaan, Liechtenstein.
Polymers
|July 15, 2026
Summary
Developing 3D printed denture bases with high impact resistance is crucial. This study optimized formulations using a triblock copolymer and silica nanoparticles, achieving superior mechanical properties and fracture toughness that meet ISO standards.
Area of Science:
- Materials Science
- Biomaterials Engineering
- Polymer Chemistry
Background:
- 3D printing high-impact denture bases requires materials with high flexural strength, modulus, and fracture toughness.
- Current commercial 3D printed denture bases often exhibit brittleness due to high crosslinking monomer content.
Purpose of the Study:
- To develop and evaluate DLP 3D printable denture base materials with enhanced fracture toughness and mechanical properties.
- To investigate the influence of post-curing temperature and formulation composition (triblock copolymer and silica nanoparticles) on material performance.
Main Methods:
- Formulations based on urethane dimethacrylate (DMA1) and (octahydro-4,7-methano-1H-indenyl)methyl acrylate (OMIMA) were prepared.
- A poly(ε-caprolactone)-polydimethylsiloxane-poly(ε-caprolactone) (PCL-PDMS-PCL) triblock copolymer (BCP1) and fumed silica (SiO2-NPs) were incorporated.
- Materials were 3D printed using DLP, followed by post-curing at various temperatures (RT, 60°C, 80°C, 100°C, 120°C).
Main Results:
- Post-curing temperature significantly affected the glass transition temperature (Tg) and mechanical properties; 100°C was optimal.
- A formulation with 8.0 wt% BCP1 and 10.0 wt% SiO2-NPs achieved flexural strength (FS) of 67.5 MPa, flexural modulus (FM) of 2450 MPa, fracture toughness (Kmax) of 2.11 MPa·m1/2, and work of fracture (Wf) of 1109 J·m-2.
- This optimized material surpassed the performance of commercial denture bases (Printodent® GR-14.2 and Lucitone Digital Print™ 3D) in key mechanical properties, particularly fracture toughness.
Conclusions:
- The developed 3D printable material, optimized with BCP1 and SiO2-NPs and post-cured at 100°C, meets and exceeds ISO 20795-1:2013 requirements for denture bases.
- This formulation offers a promising alternative for producing high-impact, fracture-tough 3D printed denture bases with improved performance over existing commercial options.
