Effect of air-borne particle abrasion and tribochemical silica coating on surface characteristics, mechanical behavior, and bonding performance of 3D-printed resin-based materials

Abstract

Abstract Objectives This study evaluated how air-abrasion material, application time, and aging affect the surface characteristics, mechanical behavior, and bonding performance of three-dimensionally (3D) printed resin. Methods Specimens were treated with aluminum oxide (Al₂O₃) or tribochemical silica coating (SiO₂) for 5, 10, and 15 s (50 μm, 2 bar). Surface roughness (Ra), flexural strength, elastic modulus, and shear bond strength (SBS) were measured. Aging included 5,000 thermocycles. Data were analyzed using ANOVA and Tukey’s test (α = 0.05). Results Roughness was significantly affected by the abrasive material, application time and their interaction ( p < 0.001). Al₂O₃ produced a time-dependent increase in roughness, whereas SiO₂ remained stable across intervals. Flexural strength was significantly reduced in all treated groups relative to the untreated control ( p < 0.001). Elastic modulus was affected by surface conditioning, while aging ( p = 0.979) and interaction effects ( p = 0.966) were not significant. SBS was significantly influenced by abrasive material and application time, but not by aging or interaction effects ( p > 0.05). SiO₂ showed more stable bonding across time, while Al₂O₃ was time-dependent. Conclusion Both surface-conditioning protocols improved bond strength. Tribochemical silica coating provided higher bond strength while more consistently preserving the mechanical properties of the printed resin, and a 10 s application was sufficient, as extending the treatment to 15 s provided no additional benefit under the conditions evaluated. Increased surface roughness did not necessarily result in improved bond strength. Clinical relevance Tribochemical silica coating offers more predictable bonding outcomes for 3D-printed restorations, particularly when precise chairside application times cannot be guaranteed, thereby minimizing the risk of adhesive failure.