Influence of handheld nonthermal plasma on shear bond strength of polyaryletherketone to resin-matrix cement

Background/purpose: Challenges exist regarding the bonding efficiency of polyaryletherketone (PAEK), a high-performance thermoplastic, attributed to its chemical inertness and hydrophobic surface, hindering effective bonding with resin-matrix cement. This research explored the impact of handheld nonthermal plasma (HNP), under varying operational parameters, on PAEK surface wettability and changes in bonding performance with cement. Materials and methods: Three types of disc-shaped PEAK specimens were prepared, with surface treatments categorized as grinding, airborne-particle abrasion (APB), and HNP. Surface wettability was analyzed using a contact angle analyzer (n = 10). Specimens were bonded with resin cement and subjected to artificial aging tests: distilled water bath (NA), thermocycling, and highly accelerated stress tests (n = 10 for each test). Shear bond strength (SBS) was measured, failure modes were analyzed, and statistical analyses were conducted. Results: The HNP markedly improved PAEK surface wettability, achieving superhydrophilicity (P < 0.05). This effect intensified with extended operation times (30 or 60 s) and reduced elapsed times (<30 s). HNP-treated PAEK exhibited higher SBS than APB (P < 0.05) and maintained bonding durability after artificial aging, particularly in ketone-enriched variants. Failure analysis revealed predominantly adhesive failure under APB–NA treatment, mixture failures under HNP–NA treatment and postaging, but no cohesive failure. Conclusion: The HNP device benefits dental settings by transforming the PAEK surface into superhydrophilic properties, thereby improving PAEK–cement bonding. It significantly enhances bond durability within 30 s of operation and after a 30 s elapsed period. It is noteworthy that ketone-enriched PAEK demonstrates markedly improved bonding performance.