This study compared the dimensional stability and dehydration of a thermoplastic polycarbonate denture base resin with two conventional polymethyl methacrylate denture base resins. Maxillary complete dentures were fabricated from the three denture materials and the accuracy of fit along the posterior palatal border of the cast used in processing was measured. Measurements were conducted at five palatal locations immediately after processing and at 7 and 30 days during immersion in water (23 degrees C) and at 7 and 30 days during dehydration (23 degrees C, 65-75% relative humidity). Percentage mass loss during dehydration was determined with an electronic balance. The thermoplastic material was separately compared with each of the conventional resins using a modified Welch two-sample t-test, with a Bonferroni correction for P values. For mean palatal dimensional change, the thermoplastic resin was generally not statistically different from the conventional resins after processing and during immersion (P > or = 0.06), but was generally less than the conventional resins during dehydration (P < or = 0.02). For mean percentage mass loss, the thermoplastic resin consistently showed much smaller, statistically significant values compared with the conventional resins (P < 0.001). It was concluded that the thermoplastic resin should show dimensional changes in service comparable with the conventional resins, but less dimensional change caused by dehydration.
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