RESUMO
Aim The aim of this study is to evaluate and compare the microhardness and polymerization shrinkage of polymethyl methacrylate reinforced with residual zirconia. Materials and methods A total of 360 resin samples were fabricated, with dimensions of 12 mm × 12 mm × 3 mm and 12 mm × 8 mm × 6 mm. Zirconia dust (40% by weight) was added to 180 of these samples. The study included four groups: Group A (autopolymerizing acrylic resin), Group H (heat-polymerizing acrylic resin), Group ZA (autopolymerizing acrylic resin with zirconia dust), and Group ZH (heat-polymerizing acrylic resin with zirconia dust). Each group consisted of 90 samples, with 45 samples used for evaluating microhardness and 45 samples for assessing polymerization shrinkage. Results Group ZH exhibited the highest microhardness at 6.06 ± 0.31 GPa. It also recorded the lowest shrinkage values, measuring 52.11 ± 3.21 mm³. Tukey's honestly significant difference test revealed that microhardness was significantly higher in Group ZA (4.53 ± 0.29 GPa) compared to Group A (3.51 ± 0.25 GPa). However, Group H (5.42 ± 0.26 GPa) demonstrated greater hardness than Group ZA. Regarding shrinkage, the addition of zirconia dust resulted in reduced values, with Group ZA (73.93 ± 3.55 mm³) showing less shrinkage compared to Group A (91.9 ± 6.38 mm³). Similarly, Group ZH (52.11 ± 3.21 mm³) had lower shrinkage than Group H (66.71 ± 5.97 mm³). Group A exhibited the highest shrinkage among all the groups. Conclusion Within the limitations of this study, it can be concluded that there is an increase in hardness and a decrease in shrinkage values of the resin with the addition of zirconia dust in heat and autopolymerizing acrylic resin used for the fabrication of provisional restorations. Zirconia-incorporated heat-activated resin showed superior microhardness and decreased shrinkage values. Although the addition of residual zirconia to autopolymerized samples demonstrated better hardness, it was observed that pure heat-polymerized samples showed greater hardness. Reusing computer-aided design and computer-aided manufacturing powder waste can cut down on economic losses and aid in environmental sustainability.