Synthesis and evaluation of novel urethane macromonomers for the formulation of fracture tough 3D printable dental materials.

3D printing of materials which combine fracture toughness, high modulus and high strength is quite challenging. Most commercially available 3D printing resins contain a mixture of multifunctional (meth)acrylates. The resulting 3D printed materials are therefore brittle and not adapted for the preparation of denture bases. For this reason, this article focuses on toughening by incorporation of triblock copolymers in methacrylate-based materials. In a first step, three urethane dimethacrylates with various alkyl spacer length were synthesized in a one-pot two-step synthesis. Each monomer was combined with 2-phenoxyethyl methacrylate as a monofunctional monomer and a polycaprolactone-polydimethylsiloxane-polycaprolactone triblock copolymer was added as toughener. The formation of nanostructures via self-assembly was proven by small angle X-ray scattering (SAXS) and transmission electron microscopy (TEM). The addition of the triblock copolymer resulted in a strong increase in fracture toughness for all mixtures. The nature of the urethane dimethacrylate had a significant impact on fracture toughness and flexural strength and modulus of the cured materials. Most promising systems were also investigated via dynamic fatigue propagation da/dN measurements, confirming that the toughening also works under dynamic load. By carefully selecting the length of the urethane dimethacrylate spacer and the amount of block copolymer, materials with the desired physical properties could be efficiently formulated. Especially the formulation containing the medium alkyl spacer length (DMA2/PEMA) and 5 wt% BCP1 (block copolymer), exhibits excellent mechanical properties and high fracture toughness.

Influence of the hydroperoxide structure on the reactivity and mechanical properties of self-cure dental composites.

OBJECTIVES: Hydroperoxides are key constituents of two-component dental materials. The objective of this study was to evaluate the influence of the hydroperoxide structure on the reactivity and on the mechanical properties of self-cure composites. METHODS: Hydroperoxides HP1-3 were synthesized by selective catalytic oxidation of the corresponding para-substituted cumene precursors and isolated in high purity. They were characterized by 1H NMR and 13C NMR spectroscopy. 16 self-cure composites, based on the redox initiator system hydroperoxide (Cumene hydroperoxide (CHP), HP1-3 or tert.-Amyl hydroperoxide (TAH))/polymerizable thiourea ATU1/copper(II) acetylacetonate, were formulated in Sulzer Mixpac two-component syringes. An equimolar hydroperoxide/ATU1 ratio was selected for each self-cure composite. The reactivity and the final double-bond conversions obtained with these two-component materials was assessed using RT-FTIR spectroscopy. The flexural strength and modulus were measured using a three-point bending setup, after storage of the specimens for 45 min at 37 °C (dry) and for 24 h in water at 37 °C. The working time of each self-cure composite was measured using an oscillating rheometer. RESULTS: CHP derivatives bearing an electron withdrawing group (HP2: ester or HP3: nitrile) in the para position were found to be more reactive than CHP, whereas the compound bearing an electron donating group (tert-butyl, HP1) was less reactive; molecular modelling data were reported for a better understanding of this structure/reactivity/efficiency relationship. All CHP derivatives were more reactive than the aliphatic hydroperoxide TAH. Excellent mechanical properties were obtained with self-cure composites containing either CHP or a para-functionalized CHP derivative. By carefully selecting the amounts of oxidizing/reducing agents and metal catalyst, suitable working times can be obtained with all evaluated hydroperoxides. HP3, thanks to its high reactivity, is nonetheless the most promising compound. SIGNIFICANCE: The curing rate of self-cure composites can be adapted by modifying the structure of the hydroperoxide. In agreement with molecular modelling data, the incorporation of CHP derivatives bearing an electron withdrawing group in the para position is particularly attractive. Indeed, due to a significant reactivity enhancement, the desired properties (working time, flexural strength/modulus) can be obtained by incorporating moderate amounts of hydroperoxide/acylthiourea as well as particularly low contents of metal catalyst to the two-component dental materials.

Acylthiourea oligomers as promising reducing agents for dimethacrylate-based two-component dental materials.

OBJECTIVES: Currently used thiourea-based two-component dental materials may release bitter compounds if they are not properly cured. To address this issue, the objective of this study was to evaluate the potential of acylthiourea oligomers as reducing agents for the development of self-cure composites. METHODS: Acylthiourea oligomers ATUO1-3 were synthesized via cotelomerization of the acylthiourea methacrylate ATU1 with butyl methacrylate. They were characterized by 1H NMR spectroscopy and size exclusion chromatography. Self-cure composites based on the redox initiator system cumene hydroperoxide/acylthiourea oligomer/copper(II) acetylacetonate were formulated. The flexural strength and modulus were measured using a three-point bending setup. The double bond conversions were determined using NIR spectroscopy. The working time of each self-cure composite was measured using an oscillating rheometer. Leaching experiments using light-cure composites were performed in DMSO-d6. RESULTS: Acylthiourea oligomers ATUO1-3 were successfully synthesized in good yields. Both the oligomer molecular weight and the amount of thiourea groups were varied. Self-cure composites containing ATUO1 or ATUO2 as reducing agents exhibited excellent mechanical properties and high double-bond conversions. The amounts of reducing agent, cumene hydroperoxide and copper(II) acetylacetonate were shown to have a significant impact on the working time. Moreover, a correlation between flexural modulus and the amount of metal salt was clearly established. Self-cure composites containing the oligomer ATUO1 exhibited a longer working time than materials containing ATU1 or acetylthiourea. Contrary to acetylthiourea, ATUO1 was not able to leach out of light-cured composites. SIGNIFICANCE: Acylthiourea oligomers are promising reducing agents for the formulation of two-component dental materials that do not induce a bitter taste in mouth.

Polymerizable thioureas as innovative reducing agents for self-cured and dual-cured dental materials.

OBJECTIVE: To evaluate polymerizable acylthioureas as reducing agents in two-component dental materials. METHODS: Acylthioureas 1 and 2 were synthesized and characterized by 1H and 13C NMR spectroscopy. Self-cured composites based on the redox initiator system cumene hydroperoxide/acylthiourea 1 or 2/copper(II) acetylacetonate were formulated. Various amounts of cumene hydroperoxide, acylthiourea and copper(II) acetylacetonate were used. An equimolar cumene hydroperoxide/acylthiourea ratio was selected for each self-cured composite. The reactivity and the final double-bond conversions obtained with these two-component materials was assessed using RT-FTIR spectroscopy. The flexural strength and modulus were measured using a three-point bending setup, after storage of the specimens for 45 min at 37 °C (dry) and for 24 h in water at 37 °C. The working time of each composite was determined using an oscillating rheometer. RESULTS: Acylthioureas 1 and 2 were synthesized in three to four steps. In combination with cumene hydroperoxide and copper(II) acetylacetonate, both prepared compounds were found to be effective reducing agents. The higher the amount of cumene hydroperoxide and acylthiourea in the self-cured composite, the higher the flexural modulus and the faster the polymerization (lower working times). Similarly, it was shown that increased copper(II) acetylacetonate amounts result in an acceleration of the curing as well as in an improvement of the mechanical properties. The self-cured composite containing 1.25 wt% of cumene hydroperoxide in the monomer mixture of the first paste and 2.00 wt% of acylthiourea 1 in the monomer mixture of the second one provided excellent mechanical properties as well as an optimal working time. SIGNIFICANCE: Polymerizable acylthioureas can be used as reducing agents in two-component dental materials. Due to the presence of the methacrylate group, such structures should be efficiently incorporated into the network during polymerization and should not leach out of the composite after curing. As a result, such dental materials are not expected to exhibit bitterness properties.

High refractive index monofunctional monomers as promising diluents for dental composites.

OBJECTIVES: To evaluate high refractive index methacrylates as diluents for the formulation of radiopaque esthetic bulk-fill composites. METHODS: 2-(4-Cumylphenoxy)ethyl methacrylate 1, 2-(2-phenylphenoxy)ethyl methacrylate 2 and 2-[2-(2-phenylphenoxy)ethoxy]ethyl methacrylate 3 were synthesized and characterized by 1H NMR spectroscopy. The reactivity of each monomer was studied using photo-DSC. Bulk-fill composites based on monomers 1-3 were formulated. Translucency (before and after light cure) was measured using a spectrophotometer. The depth of cure and the water sorption of these materials were determined according to ISO 4049. The flexural strength and modulus of elasticity were measured using a three-point bending setup, according to ISO 4049. The shrinkage force was assessed based on a method described by Watts et al. using a universal testing machine. RESULTS: Monomers 1-3 were easily synthesized in two steps. They exhibit a low viscosity and a high refractive index (1.553-1.573). Monofunctional methacrylates 1-3 were found to be more reactive than triethylene glycol dimethacrylate (TEGDMA). Bulk-fill composites based on these monomers were successfully prepared. They exhibit a high depth of cure and excellent esthetic properties (low transparency). These composites provide higher flexural modulus as well as lower water sorption than a corresponding material based on TEGDMA. Methacrylates 1 and 3 are particularly interesting as they led to composites showing lower shrinkage force. SIGNIFICANCE: Methacrylates 1-3 are promising diluents for the formulation of highly esthetic radiopaque bulk-fill composites.