Preparation of ZrO2–ZnO-Poly-Methyl-Methacrylate Composite with Enhanced Physical and Mechanical Properties for Dentistry

Abstract

Poly-methyl-methacrylate (PMMA) is the most widely used denture material for various dental applications. There are certain limitations associated with PMMA, such as its mechanical strength, dimensional stability and biocompatibility. In this study, efforts have been made to overcome these shortcomings by using ZrO<inf>2</inf> and ZnO as fillers. The main motive of the study is to fabricate ZrO<inf>2</inf> and ZnO reinforced PMMA composites with superior physical and mechanical properties. Herein, numerous composites were synthesized within a system [(95−x) PMMA + 5 ZrO<inf>2</inf> + x ZnO)] (x = 2, 4, 6 & 8% wt.) using a conventional heat cure method. A comprehensive evaluation of the PMMA-ZrO<inf>2</inf>–ZnO (PZZ) composites was carried out through both theoretical and experimental density measurements, along with a range of characterization techniques including XRD, SEM, compression and three-point bending tests, water sorption analysis, tribological testing, hardness assessment, and biological assays such as MTT, DAPI, DCFH-DA, and trypan blue staining. As the ZnO content increased, there was a corresponding rise in the density, crystallinity percentage, Young’s modulus, and flexural modulus of the composites. However, an increase in ZnO content led to a reduction in compressive strength, fracture toughness, and flexural strength of the PZZ composites. Biological evaluation indicated that cell viability was highest in composites with lower ZnO concentrations. Overall, this study provides comprehensive insights into the physical, mechanical, and biological properties of the synthesized PMMA-ZrO<inf>2</inf>–ZnO composites. © The Author(s), under exclusive licence to Springer Science+Business Media, LLC, part of Springer Nature 2025.