Impact of printing layer thickness on the flexural strength of nanocomposite 3D printed resins: An in vitro comparative study

Background: This study evaluated the influence of various printing layer thicknesses with silicon dioxide nanoparticles (SiO₂NPs) incorporated as a reinforcement material on the flexural strength of 3D-printed denture base resins. Material and Methods: Asiga (DentaBASE, Asiga, Erfurt, Germany) and NextDent (Denture 3D+, NextDent B.V., Soesterberg, The Netherlands) 3D-printed resins were modified with different concentrations of SiO₂NPs (0.25 % and 0.5 wt%). A total of 180 specimens (bar-shaped, 64 × 10 × 3.3 mm) were fabricated (N = 90/resin). Each resin was subdivided into three groups (n = 30) according to the SiO₂NP concentration (0 %, 0.25 %, and 0.5 wt%) Each concentration was divided into three groups (n = 10) according to the printing layer thickness (50 µm, 75 µm, and 100 µm). Specimens were printed according to the manufacturer's instructions and then subjected to 10,000 thermal cycles. A three-point bending test was used to measure the flexural strength (MPa). One-way analysis of variance (ANOVA) and Tukey's post hoc tests were used to analyze the data (α = 0.05). Results: For both resins, printing layer thicknesses of 50 µm and 75 µm exhibited significantly higher flexural strength than 100 µm (P < 0.001). The 50 µm thickness showed the greatest flexural strength values (81.65 ± 4.77 MPa and 84.59 ± 6.21 MPa for Asiga and NextDent, respectively). The 100 µm thickness showed the lowest flexural strength values (74.35 ± 5.37 and 73.66 ± 5.55 MPa) for Asiga and NextDent, respectively. The flexural strength significantly increased with the addition of SiO₂NPs with printing layer thicknesses of 50 µm and 75 µm (P < 0.001), whereas the modified and unmodified groups printed with a 100 µm layer thickness did not differ significantly. Asiga 0.25 %/50 µm and NextDent 0.5 %/50 µm showed the highest flexural strength values (97.32 ± 6.82 MPa and 97.54 ± 7.04 MPa, respectively). Scanning electron microscopy fractured surfaces analysis revealed more lamellae and irregularities with lower printing layer thicknesses and SiO₂NP concentrations. Conclusion: The flexural strength increased with printing layer thicknesses of 50 µm or 75 µm combined with SiO₂NP reinforcement.