Abstract :
[en] Objective This study evaluated the mechanical and fatigue properties of an experimental high-filler-content 3D-printable dental composite incorporating a novel silanization process (Magnus), designed to increase filler content without increasing viscosity and to enhance the filler–resin interface, in comparison with commercial printed and milled composite materials.
Methods Magnus specimens were fabricated by MSLA (Phrozen). They were compared with 3D-printed OnX Tough2 (Sprintray) and milled Grandio CAD-CAM composite blocks (Voco) produced following manufacturer’s recommendations. Bar specimens underwent three-point flexural testing (n=30/material) and cyclic flexural fatigue at 150 MPa (1 Hz; n=20/material). All tests were conducted in a 36°C water bath. Vickers microhardness, filler content, resin viscosity and degree of conversion were assessed.
Results Magnus exhibited the highest filler content reported (~70 wt%, 53 vol%), approximately twice that of OnX Tough2 (~35 wt%, ~22 vol%), while maintaining lower shear viscosity. At 150 MPa, Magnus demonstrated flexural fatigue resistance 4.1-fold higher than Grandio blocs and approximately 2,100-fold higher than OnX Tough2. Flexural strength was equivalent to Grandio blocs (209.7 vs 219.3 MPa), with similar Weibull modulus. Flexural modulus was 3.2-fold higher than OnX Tough2 (7.4 vs 2.3 GPa). Fracture energy and microhardness were markedly higher than OnX Tough2. Degree of conversion exceeded 95%.
Significance Under clinically relevant wet testing conditions, this very high-filler-content 3D-printable composite maintained low viscosity while achieving markedly superior fatigue resistance compared with the tested printed and milled materials and flexural strength comparable to the milled reference, thereby bridging the mechanical performance gap between printed and milled restorative materials.
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