Purpose: This study compared surface wettability, roughness, porosity, and hardness of milled (IvoBase CAD), 3D-printed (DentaBase, a light-cured resin), and conventional (heat- polymerized/injection-molded) PMMA denture base materials to assess their clinical suitability. Materials and methods: A total of 40 specimens (15×10×3.3 mm) from four different types of denture base materials (IvoBase CAD, DentaBase 3D Printed, ProBase Hot Heat Polymerized, and IvoBase High-impact Injection Molded Resin) were fabricated according to the manufacturer’s instructions. Surface properties were evaluated by using the sessile drop method to measure wettability, digital laser profilometer to measure surface roughness, the gravimetric method to measure porosity, and Vickers micro hardness test to measure surface hardness. Statistical analyses were performed using ANOVA and a relative post hoc test (P value ≤ 0.05). Results: Milled and 3D-printed materials showed significantly lower roughness (0.15–0.12 µm) vs. conventional groups (0.16–0.20 µm; p<0.001). Wettability and hardness varied significantly (p<0.001), with DentaBase exhibiting the highest hardness (23.94 VHN). Porosity did not differ (p=0.633). Conclusions: Milled and 3D-printed resins demonstrated better surface properties, suggesting clinical advantages in reducing microbial adhesion and improving durability. However, heat-polymerized PMMA remains a viable option for specific applications.
