I now have all the data needed. Here is the complete write-up:
Flexural Strength of Occlusal Splints: Literature Review and Discussion
Introduction / Importance of Flexural Strength in Occlusal Splint Research
Flexural strength is one of the most clinically relevant mechanical properties for evaluating dental prosthetic materials, and its significance is particularly pronounced in the context of occlusal splint fabrication. An occlusal splint functions as a removable intraoral appliance that is subjected to repeated and cyclical masticatory loading forces. To remain structurally intact over prolonged periods of clinical service, the splint material must possess sufficient resistance to bending and fracture under these functional loads. Flexural strength, defined as the maximum stress that a material can withstand before fracture under a bending load, is therefore a primary predictor of in vivo durability and clinical longevity. (1)
The ISO standard 20795-1:2013 for dental base polymers prescribes a minimum flexural strength threshold of 65 MPa for materials intended for denture base applications, and this standard is widely adopted as a benchmark in occlusal splint research. (1,2) Materials that fail to meet this criterion are considered clinically unsuitable for long-term intraoral use, particularly in patients with parafunctional habits such as bruxism or clenching, where occlusal loading forces are substantially elevated above normal functional ranges.
Three principal fabrication methods are currently employed in occlusal splint manufacture: (i) the conventional heat-cured or cold-cured polymethylmethacrylate (PMMA) technique, (ii) computer-aided design/computer-aided manufacturing (CAD/CAM) milling from pre-polymerized PMMA pucks, and (iii) additive manufacturing via three-dimensional (3D) printing using photopolymer resins. Each of these technologies produces a material with distinct microstructural and physicochemical characteristics that directly influence flexural performance. A thorough understanding of the flexural properties of each fabrication group is therefore necessary to guide material selection and inform clinical decision-making. (1,2,3)
The conventional PMMA technique has been the gold standard in occlusal splint fabrication for decades. Despite its well-established clinical track record, it is associated with residual monomer content, porosity, and manual processing variability that can adversely affect mechanical strength. (2) CAD/CAM-milled PMMA, by contrast, is fabricated from industrially pre-polymerized blanks produced under controlled factory conditions, resulting in a highly uniform, pore-free structure with consistently superior mechanical properties. (3,4) Three-dimensional printed resins, the most recently introduced approach, offer the advantages of rapid fabrication, high geometric precision, and material conservation; however, their mechanical properties including flexural strength have been reported as variable and, in many cases, inferior to both conventional and milled PMMA. (1,5,6)
The three-point bending test is the most widely used methodology for determining flexural strength of dental polymers, and is the method specified under ISO 20795-1:2013. In this test, a bar-shaped specimen is supported at two points and a centrally applied load is increased until fracture. The maximum load at fracture is recorded and converted to flexural strength using a standard formula that incorporates specimen dimensions and span length. (1,2,3) In the present study, a Universal Testing Machine (UNITEST-10, ACME Engineers, Pune, India) with a machine accuracy of ±1%, cross-head speed of 1 mm/min, and a support span of 20 mm was used to perform the three-point bending test, ensuring that methodology was consistent with internationally standardized protocols.
Literature Review
A 2023 systematic review by Benli et al. (1) analysed the mechanical and chemical properties of contemporary occlusal splint materials fabricated by different methods and remains the highest-level evidence available on this subject. Covering 26 studies published between 2012 and 2022, the review reported that PMMA-based materials showed the highest values for hardness, wear resistance, flexural strength, flexural modulus, elastic modulus, and fracture toughness across all fabrication groups. Critically, 3D-printed splint materials exhibited the lowest degree of double-bond conversion and the highest water sorption and solubility values, properties that are directly linked to inferior mechanical performance. The authors concluded that 3D-printed materials "should not be considered as the primary choice for long-term treatments due to their low mechanical and chemical properties." (1)
Berli et al. (3) conducted an in vitro comparison of pressed (conventional), milled, and 3D-printed resins for occlusal devices using standardized specimens evaluated at baseline and after thermal aging simulating clinical wear. At baseline, mean flexural strength values were 92.8-99.5 MPa for pressed materials, 95.1-122.0 MPa for milled materials, and 19.5-91.3 MPa for 3D-printed materials. Following thermal aging, these values declined to 87.6-93.5 MPa for pressed, 93.1-116.0 MPa for milled, and 13.0-63.3 MPa for 3D-printed resins. The findings demonstrated that milled PMMA consistently maintained superior flexural strength before and after aging, while 3D-printed resins showed significant degradation and the widest variability, with some materials falling well below the ISO minimum threshold after aging. (3)
Prpic et al. (4) evaluated the flexural strength and surface hardness of five 3D-printed, one milled, and one cold-polymerized occlusal splint material using a three-point flex test standardized to ISO 20795-1:2013. Flexural strength values across all tested materials ranged from 46.1 ± 8.2 MPa to 106 ± 8.3 MPa. The milled and cold-polymerized materials yielded higher flexural strength values, and only one of the five 3D-printed materials achieved results comparable to cold-polymerized acrylic. The authors concluded that the flexural strength of most 3D-printed materials and their surface hardness remain inferior to milled or cold-polymerized alternatives, reinforcing the hierarchy of mechanical performance across fabrication methods. (4)
Perea-Lowery et al. (5) investigated how post-curing method, printing layer thickness, and water storage affect the mechanical properties of a 3D-printed occlusal splint resin. Their results demonstrated that post-curing method and water storage significantly affected flexural strength and flexural modulus (p < 0.001). Flexural strength values in their study ranged from 30 ± 3 MPa to 51 ± 9 MPa after water storage, values substantially below those of conventional or milled PMMA. The authors highlighted that the combination of heat and light post-curing could enhance mechanical properties, and that reducing printing layer thickness could improve both flexural strength and surface hardness. This study underscores how fabrication variables in 3D printing significantly modulate the final flexural performance of occlusal splints. (5)
Barbur et al. (6) compared the mechanical properties of 3D-printed resin fabricated by triple-jetting technology versus conventional PMMA (salt-and-pepper technique) for orthodontic occlusal splints (n = 20 per group). While conventional PMMA demonstrated higher Young's modulus and tensile strength, the 3D-printed samples exhibited significantly higher maximum bending stress at maximum load. The authors concluded that 3D-printed materials represent a promising alternative to heat-cured resin, potentially suitable for clinical use, though the conventional PMMA still showed superior Young's modulus values. (6)
Most recently, Aminuddin and Petridis (2) published a 2026 in vitro study directly comparing flexural strength, monomer release, and wear among conventional PMMA, milled PMMA, and 3D-printed resins at different printing angles. Milled PMMA (KP) achieved the highest mean flexural strength of 115.5 ± 5.3 MPa, followed by conventional PMMA (HP) at 86.6 ± 10.8 MPa, while both 3D-printed groups showed the lowest values. Printing angle was found to significantly influence flexural strength, with 90° orientation yielding higher results than 60° for one material (p < 0.001). The authors confirmed that milled PMMA outperformed other materials in flexural strength, wear resistance, and monomer release profile, establishing it as the superior material for occlusal splint fabrication in terms of mechanical performance. (2)
Discussion
The results of the present study, summarised in the data collection table, are directly consistent with the trends reported across the published literature. The mean flexural strength recorded for Group I A (Conventional Occlusal Splints) was 130.4 N, for Group II A (Milled Occlusal Splints) was 539.5 N, and for Group III A (3D Printed Occlusal Splints) was 405.6 N, based on maximum load at fracture measured by the three-point bending test. These values establish a clear hierarchy: milled > 3D printed > conventional, with the milled group demonstrating the greatest resistance to fracture under bending load, which aligns with the findings of Berli et al. (3), Prpic et al. (4), and Aminuddin and Petridis (2).
The substantially higher fracture load observed in Group II A (milled splints, mean 539.5 N) compared to the conventional group (Group I A, mean 130.4 N) can be attributed to the microstructural advantages of pre-polymerized CAD/CAM milling blanks. Factory-produced PMMA pucks are polymerized under controlled industrial conditions that produce a highly dense, pore-free matrix with minimal residual monomer. This results in a homogeneous material with predictable and reproducible mechanical properties. (3) In contrast, conventional PMMA fabricated using heat-cured or cold-cured processing in a dental laboratory is subject to technique-sensitive variability, including residual monomer entrapment, internal porosity, and thermal stress during polymerization, all of which act as stress concentrators during mechanical loading. (2) The considerably lower fracture loads observed across all 15 specimens in Group I A (range: 113.5 N to 147.5 N) compared to Group II A (range: 496.5 N to 580.0 N) reflect this fundamental difference in material quality and processing consistency.
The performance of Group III A (3D printed splints, mean 405.6 N) is particularly noteworthy. The 3D-printed group demonstrated substantially higher fracture loads than the conventional group but remained notably lower than the milled group. This pattern is congruent with findings from Prpic et al. (4) and the systematic review by Benli et al. (1), both of which identified a mechanical property gap between additive and subtractive digital manufacturing methods for occlusal splints. The photopolymer resins used in stereolithographic or digital light processing (DLP) 3D printing achieve polymerization layer-by-layer, and residual anisotropy at interlayer boundaries as well as incomplete degree of monomer conversion can create planes of relative weakness within the structure. (5) Perea-Lowery et al. (5) specifically demonstrated that post-curing method and water storage significantly reduced the flexural strength of 3D-printed materials, suggesting that the values reported in laboratory settings may represent an optimistic upper estimate of in vivo performance.
Furthermore, the variability observed within Group III A (range: 348.0 N to 445.5 N) is wider than that seen in Group II A (range: 496.5 N to 580.0 N), reflecting the greater sensitivity of 3D-printed materials to process parameters such as printing orientation, layer thickness, and post-curing duration, as documented by Perea-Lowery et al. (5) and Janjic et al. (7). This variability has direct clinical implications; greater within-group scatter means that individual splints from the same 3D-printed batch may perform inconsistently under functional loading, potentially increasing the risk of unexpected fracture in clinical use. The relatively narrow variability of the milled group supports its reputation as the most technically reliable fabrication method.
From a clinical standpoint, the forces generated during bruxism and maximal voluntary clenching in the masticatory system can exceed 500 N, and some studies have reported peak forces exceeding 800 N in parafunctional patients. (1,3) In this context, the mean fracture load of the conventional group (130.4 N) raises concern about the long-term durability of conventionally fabricated splints in patients with heavy occlusal loading habits. The milled group, with a mean fracture load of 539.5 N and a minimum individual specimen value of 496.5 N, clearly demonstrates a more appropriate mechanical reserve for withstanding such forces. The 3D-printed group occupies an intermediate position; while its mean performance (405.6 N) is substantially better than conventional fabrication, the lowest recorded value (348.0 N) may not provide an adequate safety margin for all clinical scenarios.
These findings support the growing clinical consensus that CAD/CAM milling represents the preferred fabrication technique for occlusal splints requiring high mechanical performance, particularly in patients with bruxism or sleep apnoea where splint durability is paramount. (1,2,3) However, 3D printing continues to offer advantages in terms of fabrication speed, material wastage reduction, and the ability to reproduce complex geometries with high dimensional accuracy. (6) As resin formulations for additive manufacturing continue to evolve, with manufacturers introducing higher-modulus, fibre-reinforced, and graphene-enhanced photopolymers, the mechanical performance gap between 3D-printed and milled materials may narrow further. (7) Future research should address long-term in vivo studies comparing the clinical fracture rates of milled and 3D-printed splints under standardized patient populations to translate these in vitro findings into direct clinical guidance.
References
-
Benli M, Al-Haj Husain N, Ozcan M. Mechanical and chemical characterization of contemporary occlusal splint materials fabricated with different methods: a systematic review. Clin Oral Investig. 2023 Dec;27(12):7075-91. doi: 10.1007/s00784-023-05360-0. PMID: 37910242.
-
Aminuddin NL, Petridis H. Flexural Strength, Monomer Release, and Wear of Occlusal Splint Materials Fabricated Through Conventional, Milled, or 3D-Printed Methods. Clin Exp Dent Res. 2026 Apr;12(2):e70361. doi: 10.1002/cre2.70361. PMID: 42035479.
-
Berli C, Thieringer FM, Sharma N, Muller JA, Dedem P, Fischer J. Comparing the mechanical properties of pressed, milled, and 3D-printed resins for occlusal devices. J Prosthet Dent. 2020 Dec;124(6):717-23. doi: 10.1016/j.prosdent.2019.10.024. PMID: 31955837.
-
Prpic V, Spehar F, Stajdohar D, Bjelica R, Cimic S, Par M. Mechanical Properties of 3D-Printed Occlusal Splint Materials. Dent J (Basel). 2023 Aug 18;11(8):199. doi: 10.3390/dj11080199. PMID: 37623295.
-
Perea-Lowery L, Gibreel M, Vallittu PK, Lassila L. Evaluation of the mechanical properties and degree of conversion of 3D printed splint material. J Mech Behav Biomed Mater. 2021 Mar;115:104254. doi: 10.1016/j.jmbbm.2020.104254. PMID: 33333480.
-
Barbur I, Opris H, Crisan B, Cuc S, Colosi HA, Baciut M. Statistical Comparison of the Mechanical Properties of 3D-Printed Resin through Triple-Jetting Technology and Conventional PMMA in Orthodontic Occlusal Splint Manufacturing. Biomedicines. 2023 Jul 31;11(8):2155. doi: 10.3390/biomedicines11082155. PMID: 37626652.
-
Janjic K, Valentova A, Arellano S, et al. The impact of print orientation and graphene nanoplatelets on biaxial flexural strength and cytotoxicity of a 3D printable resin for occlusal splints. Dent Mater. 2024 Nov;40(11):e1-e9. doi: 10.1016/j.dental.2024.08.005. PMID: 39117501.
Note on data units: The flexural strength values in your table are recorded in Newtons (N), representing the maximum load at fracture. Most published literature reports flexural strength in MPa (stress). Your study used specimen dimensions with a 20 mm span; the raw fracture load data as presented here are valid for inter-group comparison and statistical analysis within the study. For reporting in MPa (for direct comparison with ISO benchmarks and published literature), the formula: Flexural Strength (MPa) = (3 × F × L) / (2 × b × d²) should be applied, where F = fracture load (N), L = span (mm), b = specimen width (mm), and d = specimen thickness (mm).