This study is aimed at the synthesis of antimicrobial hydroxyapatite (HAP)‐based composites for dental application by stereolithography (SLA). A micron‐sized commercial HAP was modified by methacrylate and quaternary ammonium salt, and, then, it was used in different amounts (namely 2.5, 5, and 10 wt%) as filler for a photocurable custom made resin for SLA. Thermal stability, microstructure, and particles size of the pristine (HAP) and modified HAP (mHAP) were evaluated by thermogravimetric analysis (TGA), X‐ray diffraction (XRD), and particle size analyser (CILAS). The suitability of each formulation for stereolithography process was assessed by measuring viscosity, degree of conversion (DC%) by Fourier transform infrared spectroscopy (FTIR), glass transition temperature, and thermal stability. Photo‐cured specimens for physical, mechanical, and antimicrobial testing were built by SLA. The flexural strength of the samples was measured using a 3‐point bending test method, and the fractured surface was analysed by scanning electron microscopy (SEM). The antimicrobial activity of samples was investigated against some standard microorganisms (Staphylococcus aureus, Escherichia coli, and Candida albicans), as representative Gram positive and Gram negative bacteria and fungus, respectively. The flexural strength increased with a filler content up to 5% and slightly decreased for higher content. SEM analysis confirmed the presence of uniformly distributed HAP. The incorporation of mHAP reduced the bacterial and fungal growth in dose‐dependent manner in comparison with the neat samples. Finally, a prototype of dental bite was built by SLA.
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