An in vitro evaluation of bond strength and failure behavior between 3D-printed cobalt-chromium alloy and different types of denture base resins

Objectives: This study aimed to evaluate the shear bond strength and failure behavior between cobalt-chromium (Co-Cr) alloy and different types of denture base resins (DBRs) over time. Methods: Seventy-two disk-shaped specimens (8 mm in diameter and 2 mm in thickness) were manufactured using a selective laser melting technology-based metal 3D printer. Three types of DBRs were used: heat-cure (HEA group), cold-cure (COL group), and 3D-printable (TDP group) DBRs (n = 12 per group). Each DBR specimen was fabricated as a 5 mm x 5 mm x 5 mm cube model. The specimens of the TDP group were manufactured using a digital light processing technology-based 3D printer. Half of the DBRs were stored in distilled water at 37 degrees C for 24 h, whereas the remaining half underwent thermocycling for 10,000 cycles. Shear bond strength was measured using a universal testing machine; failure modes were observed, and metal surfaces were evaluated using energy dispersive spectrometry. Results: The shear bond strength did not differ between the DBR types within the non-thermocycled groups. Contrarily, the TDP group exhibited inferior strength compared to the HEA group (P = 0.008) after thermocycling. All three types of DBRs exhibited a significant decrease in the shear bond strength and an increased tendency toward adhesive failure after thermocycling. Conclusions: The bond strength between 3D-printable DBRs and Co-Cr alloy was comparable to that of heat-and cold-cure DBRs before thermocycling. However, it exhibited a considerable weakening in comparison to heatcure DBRs after simulated short-term use. Clinical Significance: The application of 3D-printable DBR in metal framework-incorporated removable partial dentures may be feasible during the early phase of the treatment. However, its application is currently limited because the bond strength between the 3D-printable DBR and metal may weaken after short-term use. Further studies on methods to increase the bond strength between these heterogeneous materials are required.