A new method for predicting the maximum filler loading of dental resin composites based on DEM simulations and experiments.

The inorganic fillers in dental resin composites can enhance their mechanical properties and reduce polymerization shrinkage. When the usage amount of inorganic fillers is closed to maximum filler loading (MFL), the composites will usually achieve optimal performances. This study aims to develop a method that can predict the MFL of dental resin composites for the optimization of filler formulations. A method based on discrete element method (DEM) simulations and experiments was firstly developed to predict the MFL of spherical silica particles for single-level and multi-level filling. The results indicate that the presence of modifier can increase the MFL, and the MFL increment can be exponentially changed with the content of the modifier. Compared with the single-level filling, the addition of secondary fillers is beneficial to increase the MFL, and the increment can be affected by the particle size and size ratio. The prediction results show a good agreement with the experiment results. The accuracy of prediction results indicates a great potential of DEM simulations as a numerical experimental method in studying the MFL, and provides an effective method for the optimization of filler formulations. [ABSTRACT FROM AUTHOR]