The fracture resistance of polymethyl methacrylate (PMMA) the most popular denture base materials, is not satisfactory. The aim of this study is to improve the mechanical properties of PMMA by adding filler particles. Different inorganic filler particles including micronised glass flakes, acryl silane micronised, glass flakes 350nm, TiO2 and ZrO2 with different ratios by weight were incorporated into heat-cure plain PMMA and processed with optimal condition [2.5:1 Powder/ monomer ratio, conventional packing method and water bath curing for 2 hours at 95°C] to produce 12mm diameter and 2mm thick discs. Plain PMMA without additives was prepared as a test control. Three types of mechanical tests, biaxial flexure, microindentation fracture toughness and Vickers hardness were carried out on the samples. It was found that incorporating the particles did not improve the biaxial flexural strength of the resin. However, TiO2, ZrO2 and micronised glass flakes increased the fracture toughness of the resin. The hardness of PMMA was improved by the incorporation of all the particles.

The most commonly used denture base material, polymethyl methacrylate, lacks ideal mechanical properties, which are reflected in its relatively high failure rate. Several methods have been explored to reinforce the material and reduce the cost of denture repair and replacement. In this study, various surface modified filler particles at different concentrations were dispersed in conventional and high-impact denture base materials and tested for their improvement in mechanical properties. Inorganic filler particles were coated with different silane coupling agents using an ultrasonic device. The particulates were dispersed in the resin and the composites polymerised through an innovative dual-cure technique. Charpy impact test, single-edge notch three-point bend fracture toughness test and Biaxial Flexural Strength (BFS) were performed on the specimens. The results showed that mechanical properties of the denture base resin can be improved by incorporating filler particles; however, the surface characteristics, quantity and level of dispersion of the particles play critical role in the mechanical behaviour of the composites. The results of this study are a promising step towards developing more fracture-resistant denture base materials.

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