In Vitro Study of the Surface Roughness, Hardness, and Absorption of an Injection-Molded Denture Base Polymer, Manufactured under Insufficient Mold Solidification

The current study sought to investigate the changes in surface hardness, roughness, and moisture absorption of the Vertex ThermoSens polymer (Vertex Dental, 3D Systems, The Netherlands) following immersion in artificial saliva for various periods (7, 14, and 28 days). A total of 60 rectangular specimens with dimensions of 20 mm in length, 20 mm in width, and 3 mm in thickness were made. Due to insufficient mold solidification, these specimens were made utilizing the injection molding process. A Mitutoyo Surftest 4 roughness meter (Mitutoyo, Aurora, IL, USA) was used to measure the surface roughness of the test materials. The ThermoSens polymer hardness was assessed using the Shor method and D—HSD scale, while absorption was measured with a Sartorius analytical balance. Results indicated the highest mean hardness after 28 days (M = 77.6) (Surface 1) and the lowest for the control group (M = 59) (Surface 2). The maximum surface roughness occurred in direction 2.2 pre-immersion (Ra = 2.88 μm) and 7 days post-removal (Ra = 2.95 μm). The control group exhibited the lowest absorption (Wsp = 1.524 mg/mm3), with the highest mean values over 28 days (Wsp = 1.541 mg/mm3). The elevated flask and plaster temperature slowed polymer solidification, resulting in longer macromolecules and improved mechanical properties and surface features.