Objectives: The aim of the present study was determine the apical microleakage after root canal filling with different sizes of Thermafil obturators in an in vitro investigation. Methods: Forty-five extracted single rooted incisors stored in saline were used. Nine roots per group were endodontically prepared using the Profile-system to a maximum size of 40 under constant sodium hypochloride and chlorhexidine irrigation. The root length was determined by insertion of a size 10 file into the canal until it appeared at the apex. The working length was recorded 1 mm shorter. The roots were filled with the sealant AH plus and Thermafil obturators size 40 (group A), size 35 (group B), size 30 (group C), size 25 (group D) and size 20 (group E). The teeth were coated with nail varnish, 1-2mm of the apex cut off and stored in methylene blue solution for one week. After that all teeth were bisected along their long axis. Linear dye penetration (apical – coronal) was measured using a light microscope. Statistical analysis was performed using SPSS 10.0. Results: Following mean values of linear dye penetration were recorded (in µm, with standard deviation): Group A: 1917 (+/- 721); group B: 1517 (+/- 584); group C: 1483 (+/- 485); group D: 3367 (+/- 795) and group E: 4101 (+/- 1601). Statistical analysis revealed significant higher penetration depths in group D and E and no significant differences between group A, B and C (p<0.05, Tukeys test). Conclusions: Within the limitations of an in vitro investigation it can be concluded that using Thermafil obturators smaller than 30 might increase the risk of apical leakage.

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