Background. The mechanical reliability of occlusal splints and their long-term behavior are significant factors determining the clinical outcome of temporomandibular disorder (TMD) therapy. However, improvements are still needed in this area.Objectives. This in vitro study aimed to (1) compare the hardness and flexural properties of materials manufactured using 3 techniques for occlusal splint fabrication (conventional heat curing, thermoforming followed by light curing, and three-dimensional (3D) printing) and ( 2) analyze the effect of artificial aging on the properties of the materials.
Material and methods.A total of 120 disc-shaped specimens were manufactured for the Shore D hardness evaluation, and 120 bar-shaped specimens were fabricated for the flexural properties evaluation (n = 15 for each group). Each material was tested in 2 groups of specimens, non-aged and artificially aged (stored for 90 days in water at 37°C). Statistical differences were assessed using one-way or two-way parametric analysis of variance (ANOVA) with Tukey's or Šídák's post-hoc test, or the non-parametric Kruskal-Wallis test with Dunn's post-hoc test. A p-value of less than 0.05 was considered statistically significant.Results. The mechanical properties of the materials varied significantly. Among the non-aged materials, the 3D-printed resin exhibited the highest Shore D hardness (85.3D), but it decreased significantly after 90 days of water storage (80.4D, p < 0.0001). The unpolished heat curing acrylic showed the highest resistance to artificial aging (p = 0.0436). However, its hardness decreased significantly after polishing (81.0D vs. 83.4D, p = 0.0015). The conventional heat curing material also exhibited superior flexural properties (σ = 89.63 MPa, E = 2616 MPa). All tested materials were susceptible to deterioration due to aging.
Conclusions.The conventional method of occlusal splint fabrication remains the optimal choice, particularly for long-term use. However, it is still necessary to develop materials that are resistant to aging in order to ensure successful clinical performance.