Comparison of the Mechanical Properties and Surface Characteristics Between Vat Photopolymerization Resin Materials and a Polymethyl Methacrylate Disc Material

Additive manufacturing using vat photopolymerization (VPP) resin materials has gained attention for fabricating dental prostheses; however, the effects of material type and build angle on their properties remain unclear. We compared the mechanical properties of two filler-containing VPP hybrid resins, SprintRay Ceramic Crown (CC) and OnX Tough 2 (OT), with those of a conventional polymethyl methacrylate (PMMA) disc material, and evaluated the influence of build angle on surface characteristics, dimensional accuracy, and mechanical performance. Specimens were fabricated using a DLP system at build angles of 0°, 45°, and 90°. Vickers hardness, surface morphology and roughness, dimensional deviations, flexural strength, elastic modulus, and fracture energy were assessed according to relevant standards. CC exhibited significantly higher hardness and elastic modulus than PMMA and OT, whereas OT showed the highest fracture energy. Surface morphology and roughness were strongly affected by build angle, with 45° producing distinct periodic patterns and increased roughness. Dimensional evaluation revealed a tendency toward overbuilding, particularly in the vertical direction at 45°. Flexural properties were also influenced by build angle, with 45° generally providing favorable performance. Both material composition and build angle affect VPP-fabricated dental resin performance, highlighting the importance of appropriate material and processing selection for clinical applications.