Distortion behavior of heat-activated acrylic denture-base resin in conventional and long, low-temperature processing methods.

There have been many reports on fatal distortion of heat-activated acrylic denture-base resin which is still widely used in the field of removable prosthodontics. However, these reports have failed to report quantitatively on polymerization and thermal shrinkage factors. In the present study, we attempted to verify that the shrinkage of heat-activated acrylic denture-base resin was caused mainly by thermal contraction after processing. Furthermore, we examined the degree of distortion resulting from long, low-temperature processing, and compared the results with that of the conventional method. The strain gauge and thermo-couple were embedded in a specimen at the time of resin packing. The measurement started from the beginning of processing and continued until the specimen was bench-cooled and immediately before and after it was de-flasked, as well as during seven-day immersion in water at 37 degrees C. The resin expanded when processed by the conventional method. Meanwhile, mild shrinkage, possibly polymerization shrinkage, was observed when the resin was processed by the low-temperature method. This suggested that polymerization shrinkage was compensated for by thermal expansion during processing by the conventional method. Moreover, the shrinkage strains in the period from the completion of processing to immediately after de-flasking, in both the conventional and low-temperature methods, were identical to the theoretical value of thermal shrinkage which we obtained by multiplying the linear coefficients of thermal expansion by temperature differences. The shrinkage strain in the specimen processed by the low-temperature method, measured from the end of processing to immediately after de-flasking, averaged 64% of that in the specimen processed by the conventional method. The results revealed quantitatively that the shrinkage of heat-activated acrylic denture-base resin was mainly thermal shrinkage, and demonstrated the advantage of the low-temperature method in reducing thermal shrinkage.