Dimensional stability of custom impression trays is an important facto
r in determining the degree of accuracy achieved in forming a master c
ast. Such trays must remain stable over time and must not exhibit perm
anent deformation when a completed impression is removed from the oral
cavity. Measurement of the mechanical properties allows comparison be
tween various tray materials and is useful in interpreting data on str
esses incurred during removal of the completed impression. In Part I o
f this three-part series, the various mechanical properties of five tr
ay resins: one autopolymerizing polymethyl methacrylate, one light-pol
ymerizing, and three brands of thermoplastic resins were recorded and
compared. The thermoplastic resins studied in this investigation exhib
ited lower measured values for the strength and elastic modulus proper
ties than the light-polymerizing resin and the autopolymerizing polyme
thyl methacrylate resin studied.