Material Extrusion of Thermoplastic Acrylic for Intraoral Devices: Technical Feasibility and Evaluation

This study explores the technical viability of material extrusion for fabricating thermoplastic acrylic-based intraoral devices. Polymethylmethacrylate filaments were printed with various print directions, layer heights, and glass fiber reinforcements. Mechanical, thermal, and chemical properties of the parts were evaluated. Optimal combinations showed superior strength and biocompatibility over conventional acrylics. Surface finishing and aesthetics were also addressed. The results demonstrate a promising low-cost alternative to photopolymer-based systems with potential for broader medical applications.