The Influence of Filler Morphology and Loading Level on the Properties of Light-Curing Dental Composites

TL;DR

This study explores how filler shape and amount affect dental composite properties, finding that spherical nanoparticles improve performance and allow higher filler content.

Contribution

The study systematically investigates the combined effects of filler morphology and loading on mechanical and hydrolytic properties of dental composites.

Findings

Spherical SiO2 nanoparticles reduced composite viscosity, enabling higher filler loading up to 80 wt.%

Bimodal glass systems (50/50 ratio) showed optimal mechanical properties, while higher fine fractions reduced strength.

Composites with 78 wt.% filler loading achieved the highest flexural strength and modulus.

Abstract

Background/Objectives: Light-curing dental resin composites remain limited by high polymerization shrinkage, inadequate wear resistance, and elevated water sorption. The combined influence of filler shape, size, and loading level on mechanical performance and hydrolytic stability remains insufficiently understood. This study aimed to systematically investigate the effects of filler morphology and particle size distribution on the key properties of dental composites. Methods: Spherical silica (SiO2) nanoparticles (D50 = 0.50 μm) were synthesized via the Stöber method, while irregular aluminosilicate glass was used in coarse (D50 = 3.71 μm) and fine (D50 = 1.98 μm) fractions. Three composite groups were formulated: Group 1 (72 wt.% filler with 0–30% SiO2), Group 2 (maximum filler loading 76–80 wt.% with 10–30% SiO2), and Group 3 (74.5 wt.% filler with varying coarse/fine glass ratios). Flexural strength, flexural modulus, Vickers microhardness, depth of cure, water sorption, and solubility were evaluated according to ISO 4049:2019. Results: Incorporation of spherical SiO2 nanoparticles significantly reduced composite viscosity, enabling maximum filler loading to increase from 72 to 80 wt.%. All composites exceeded ISO requirements for flexural strength (80.54–118.11 MPa), depth of cure (3.01–5.65 mm), water sorption (14.61–22.87 μg/mm3), and solubility (1.20–5.90 μg/mm3). The highest flexural strength (118.11 ± 10.54 MPa) and modulus (9.26 ± 1.12 GPa) were achieved at 78 wt.% filler loading. Bimodal glass systems (50/50 ratio) demonstrated optimal mechanical properties, while higher fine fractions reduced strength. Conclusions: Spherical SiO2 nanoparticles effectively reduce viscosity and enable higher filler loading. The optimal balance between filler loading, particle shape, and size distribution should be tailored to clinical requirements, with high-strength formulations suited for posterior restorations and bimodal formulations for universal applications.

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