CLASSIFICATION OF RESINS Due to their heterogenous structure and complex nature it is difficult to classify them.

Based on the thermal behaviour, they are classified as;

Thermoplastic: Refers to resins that are softened and moulded under heat and pressure without any chemical changes occurring. They are cooled after moulding. They are fusible and are usually soluble in organic solvents. E.g., Polymethyl methacrylate, polyvinyl acrylics and polystyrene.

Thermoset: Refers to resins in which a chemical reaction takes place during moulding. The final product is chemically different from the original substance. These cannot be softened by reheating like the thermoplastic resins. They are generally infusible and insoluble. E.g., Crosslinked poly (methyl methacrylate), silicones etc.

A more exact means for classification is in terms of its structural units.

BASIC NATURE OF POLYMERS: Polymer: Denotes a molecule that is made up of many parts. The mer ending represents the simplest repeating chemical

structural unit from which the polymer is composed. Poly (methyl methacrylate) is a polymer having chemical structural units derived from methyl methacrylate. Usually any chemical possessing a molecular weight higher than 5000 is considered to be a polymer.

Monomer: The molecules from which the polymer is constructed are called monomers (one part).

Polymer molecules may be prepared from a mixture of different types of monomers and they are called co-polymers.

Molecular weight: The molecular weight of polymer molecule equals the molecular weight of the various mers multiplied by the number of mers. They may range from thousand to millions of molecular weight units depending on preparation conditions.

The molecular weight of polymers play an important role in determining its physical properties.

Degree of polymerization: Defined as the total number of mers in a polymer. The higher the molecular weight of the polymer made from a single monomer, the higher the degree of

polymerization. The strength of the resin increases with increase in the degree of polymerization until a certain molecular

weight is reached. Above this there is no change.

Molecular weight distribution: A narrow molecular weight distribution gives the most useful polymers. However most polymers have a wide range of molecular weights and so vary widely in their properties. For example, the higher the molecular weight, the higher the softening and melting points and the stiffer the plastic.

Polymerization chemistry: The term polymerization refers to a series of chain

reactions by which a macromolecule or polymer is formed from a single molecule known as monomer.

These structural units are connected to each other within the polymer molecules by bonds. Polymerization is a repetitive intermolecular reaction that is functionally capable of

proceeding indefinitely. Types: Most polymerization reactions fall into two basic types.

1)

Condensation polymerization: Condensation resins are divided into two groups: a) Those in which polymerization is accompanied by

repeated elimination of small molecules: The primary compounds react with the formation of by products such as water, halogen acids, and ammonia. The process can repeat itself and forms macromolecules. b) Those in which functional groups are repeated in the polymer chains: The mers are joined by functional groups (like amide, urethane, ester or sulfide linkages). Formation of a by-product is not necessary. E.g.,

polyurethane. In the past several condensation resins have been used to make denture bases. E.g., bakelite (phenol-

formaldehyde resin). The formation of polymers by the condensation method is rather slow. Also, it tends to stop before the

molecules have reached a truly giant size. Thus, building molecules with high molecular weights is very difficult. At present, condensation resins are not widely used in dentistry. 2) Addition polymerization: All resins employed extensively in dental procedures are produced by addition polymerization. The word polymerization when used alone means addition polymerization. Here there is no change in chemical composition and no by products are formed during the formation of macromolecules. In this type of polymer the structure of the monomer is repeated many times in the polymer. Giant molecules of almost unlimited size can be produced in this manner. Starting from an active center, one molecule at a time is added and a chain rapidly builds up, which can grow almost identifinitely as long as the supply of building blocks is available. This process is simple but not easy to control. ACRYLIC RESINS The acrylic resins are derivatives of ethylene and contain a vinyl group in their structural formula. The acrylic resins used in dentistry are the esters of; 1) 2) Acrylic acid, CH 2 =CHCOOH Methacrylic acid, CH 2 =C(CH 3 )COOH

95 percent of the complete dentures made today use one of the acrylic resins. These are available as methylmethacrylate (liquid) and poly (methyl methacrylate) (powder).

Poly(Methylmethacrylate) resins: These are widely used in dentistry to fabricate various appliances. One of the reasons for its wide popularity is the ease with which it can be processed. Although, it is a thermoplastic resin, in dentistry is not usually molded by the thermoplastic means. Rather, the liquid (monomer) methylmethacrylate is mixed with the polymer (powder). The monomer plasticizes the polymer moulded. to a doughlike consistency which can be easily

Types: Based on the method used for its activation; i) ii) iii) Heat activated resins Chemically activated resins Light activated resins

Heat-activated denture base resins: Mode o supply: Available as: 1) 2) Powder and liquid Gels sheets and cakes

Composition: LIQUID Methyl methacrylate dibutyl phthalate Glycol dimethacrylate (1-2%) Hydroquinone (0.006%) Plasticizer

Crosslinking agent Inhibitor

The liquid (monomer) is supplied in tightly sealed amber coloured bottles (to prevent evaporation and premature

polymerization by light or ultraviolet radiation on storage). POWDER Poly (methyl methacrylate) Other copolymers 5% Benzoyl peroxide Initiator Dyes Opacifiers Plasticizer

Compounds of mercuric sulfide, cadmium sulfide Zinc or titanium oxide Dibutyl phthalate Dyed organic filler Inorganic particles like glass fibers of beads -

The powder is in the form of beads or small spherical particles. The high molecular weight poly (methyl methacrylate)

dissolves in the monomer very slowly. So the following methods are used to increase the solubility. 1) By incorporating an additive. E.g., a copolymer of methyl methacrylate and ethyl acrylate. 2) By adding a plasticizer such as dibutyl phthalate, either by ball milling it with the pearls or by adding it to the monomer (8 to 10%). 3) By blending the high molecular beads with poly (methyl methacrylate) of lower molecular weight, which is more soluble in the monomer. Polymerization reaction: Polymerization is achieved by application of heat and pressure. The simplified reaction is outlined below: Powder (Polymer) + Initiator) (Reaction) Technical consideration: 1) 2) I. Compression moulding technique Injection moulding technique Compression Moulding Technique: + Liquid (Monomer) + Inhibitor) + Heat --- Polymer + Heat

(External)

This

is

the

most

commonly

used

technique

in

the

fabrication of acrylic resin dentures. Steps: 1. 2. Preparation of the wax pattern Preparation of the split mould

i)

The pattern is invested in a dental flask using dental stone or plaster.

ii)

After the stone or plaster sets, it is dewaxed by placing the flask in boiling water for not more than 5 minutes.

3.

Application of separating medium: The resin must be protected from contact with gypsum

surface for the following reasons: i) To prevent water from the mould entering into the acrylic resin. This may affect the rate of

polymerization and colour of the resin. ii) To prevent monomer penetrating into the mould material, causing plaster to adhere to the acrylic resin and producing a rough surface.

Types of separating media: The various separating media used are:

a. b. c. d. e. f. g.

Tinfoil Cellulose lacquers Solution of alginate compounds Evaporated milk Soap Sodium silicate Starches

Tin foil was the material used earlier. This is a time consuming and difficult process. It has been largely replaced by other separating media known as tinfoil substitutes.

4.

Mixing of powder and liquid: The correct proportions of polymer and monomer are

mixed. Proportion: Polymer Monomer = 3 : 1 by volume OR 2 : 1 by weight Mixing is normally carried out by placing a suitable volume of liquid into a clean, cry mixing vessel followed by slow addition of powder, allowing each powder particle to become wetted by monomer. The mixture is then stirred and allowed to stand in a closed container.

Physical stages of polymerization: After mixing polymer & monomer, it is allowed to stand in a closed mixing vessel jar. The material goes through various physical stages. No polymerization reaction takes place during these stages. But the plasticization takes place by a partial solution of the polymer in the monomer. Stage 1 Stage 2 : Wet sand stage: The polymer gradually settles into the monomer forming a fluid, incoherent mass : Sticky stage: The monomer attacks the polymer by penetrating into the polymer. The mass is sticky and stringy (cobweb like) if the mixture is touched or Stage 3 pulled apart. : Bough or gel stage: As the monomer diffuses into the polymer, the mass becomes more saturated with polymer in solution. It becomes smooth and dough like. It does not adhere to the walls of the jar. It consists of undissolved polymer particles suspended in a plastic matrix of monomer and dissolved

polymer. The mass is plastic and homogenous and Stage 4 packed into the mould at this stage. : Rubbery stage: The monomer disappears by further penetration into the polymer and evaporation. The mass is cohesive, rubber like, non plastic and

cannot be moulded.

Stage 5 5.

: Stiff.

Packing: The powder liquid mixture should be packed into the flask at the dough consistency for several reasons: i) If it is packed at the sandy or stringy stages, too much monomer will be present between the polymer particles, and the material will be of too low a viscosity to pack well and will flow out of the flask too easily. Packing too early may also result in porosity in the final denture base. ii) If packed at the rubbery to the stiff stage, the material will be too viscous to flow, and metal-tometal contact of the flask halves will not be obtained. Delayed packing will result in loss of detail in the denture, movement or fracture of the teeth and increase in the contact vertical dimension of the denture.

6.

Curing: After the final closure of the flasks, they should remain at room temperature for 30 to 60 minutes.

Sometimes this is called as Bench curing.

Curing cycle:

The curing or polymerization cycle is the technical name for the heating process employed to control the initial

propagation of polymerization in the denture mould. The curing cycle selected should depend on the thickness of the resin. Following are the recommended curing cycles. i) ii) Heat the flask in water at 60 0 to 70 0 C for 9 hours. Heat the flask at 65 0 C for 90 minutes, then boil the water for 1 hour for adequate polymerization in thinner portions.

7.

Cooling: The flask should be cooled slowly i.e.

bench cooled. If it is placed directly into tap water, warpage of the denture takes place due to differential thermal contraction of the resin and gypsum mould.

Cooling overnight is ideal. 8. Deflasking: This has to be done with care to avoid

flexing and breaking of the acrylic dentures. 9. Finishing and polishing: A suspension of finely

ground pumice in water is commonly used for polishing.

II.

Injection moulding technique: The mould space may be filled by injecting the resin under

pressure before it hardens. A sprue hole and a vent hole are

formed in the gypsum mould and the metal flask is constructed such that it will adapt to the injection moulding equipment. The soft resin is contained in the injector and is forced into the mould space as needed. The resin is injected in dough stage and kept under pressure until it has hardened. In the case of the polystyrene resin, the polymer is first softened under heat and injected while hot. The thermoplastic resin then solidifies in the mould upon cooling.

No trial closures are required with this technique. There is no difference in accuracy or physical properties as compared to compression moulding technique.

Advantages 1. Dimensional accuracy 2. Low free monomer content 3. Good impact strength

Disadvantages 1. High capital costs 2. Difficult mould design problems 3. Less craze resistance 4. Less creep resistance 5. Special flask is required

Polymerization procedure Polymerization:

When the temperature of the dough increases above 60 0 C the molecules of benzoyl peroxide decompose to form free radicals. A free radical reacts with a monomer molecule, and a new free radical is formed, which in turn gets attached to another monomer molecule. The chain reaction is thus

propagated until a termination occurs. The rate of polymerization depends upon the rate at which the free radicals of benzoyl peroxide are released. This is dependant on the temperature.

Lower temperature of polymerization results in greater molecular weight of the polymer.

Temperature rise: The polymerization reaction is exothermic. As the

temperature of water and plaster are increased from room temperature to 100 0 C in 60 minutes, the temperature of acrylic increases to the same rate until the temperature rises slightly above 70 0 C.

At this time the temperature of the resin begins to rise rapidly. At this temperature more number of benzoyl peroxide molecules are activated producing a chain reaction. Because of

this the temperature of the interior of the resin rises above the temperature of boiling water at which the resin was polymerized.

Curing cycle: The curing cycle is the technical name for the heating process employed to control the initial propagation of

polymerization in the denture mould. The recommended curing cycles are; i) ii) Heat the flask in water at 600 to 700C for 9 hours. Heat the flask at 650C for 90 minutes, then boil water for 1 hour for adequate polymerization in thinner

portions.

Apart from water bath, a variety of other methods of supplying the necessary heat to accelerate the polymerization function have been used. They include; 1. 2. 3. Steam Dry air oven 4. 5. Infrared heating Induction or dielectric heating Microwave radiation

Dry heat (electrical) 6.

Results of various processing studies have shown that equally satisfactory, but not superior, results may be obtained

with any of the methods compared to water bath method if adequate temperature control and pressure are maintained.

Polymerization methacrylate)

by

microwave

energy:

Poly

(methyl

Resin can also be polymerized by microwave energy.

Advantages: 1. It is cleaner and faster than polymerization with the conventional hot water. 2. 3. The fit of the denture is comparable or superior. Acrylic resins formulated for microwave polymerization are less prone to porosity.

Advantages 1. 2. 3. 4. 5. Good appearance High glass transition Ease of fabrication Low capital costs Good surface finish Is2

Disadvantages: 1. Radiolucency

2.

Free monomer content or formaldehyde may cause sensitization.

3. 4.

Fatigue life too short Low impact strength

Chemically activated denture base acrylic resins: The chemically activated acrylic resins polymerize at room temperature. They are also known as self-curing, cold cure or autopolymer resins.

In cold cured acrylic resins, the chemical initiator benzoyl peroxide is activated by another chemical. (dimethyl-para

toluidine) which is present in the monomer.

Therefore, the fundamental difference between heat cure and self cure resins is the method of activation of benzoyl peroxide. Composition Methyl methacrylate Dimethyl-p-toluidine Dibutyl phthalate Glycol dimethacrylate 1 to 2% Hydroquinone 0.006% Liquid Activator Plasticize Cross linking agent Inhibitor Powder Poly (methyl methacrylate) Other copolymers 5% Benzoyl peroxide Compounds of mercuric Initiator Dyes

sulfide, cadmium sulfide Zinc or titamium oxide Opacifiers Dibutyl phthalate Plasticizer Dyed organic fillers Inorganic particles like glass fibres or beads Manipulation: 1. 2. 3. 4. 5. Sprinkle on technique Adapting technique Fluid resin technique Compression moulding technique Injection moulding technique

Fluid resin technique: (Pour-type acrylic resins) The chemical composition of the pour type of denture resin is similar to the poly (methyl methacrylate) materials that are polymerized at room temperature. The principal difference is that the pour type of denture resins have high molecular weight powder particles that are much smaller and when they are mixed with monomer, the resulting mix is very fluid. Therefore they are referred as fluid resins. They are used with significantly lower powder liquid ratio, i.e., it ranges from 2:1 to 2.5:1. This aids to prevent undue increase in viscosity during mixing and pouring stages. The main difference with these materials lies in the

methods of flasking and curing. This technique most commonly involves the use of agar hydrocolloid for the mould preparation

in place of usual gypsum investment. The fluid mix is quickly poured into the mould and allowed to polymerize under pressure at 0.14 MPa (20 psi). Light-Activated Denture Base Resins This denture base material consists of a urethane

dimethacrylate matrix with an acrylic copolymer, microfine silica fillers, and a photoinitiator systems. (Camphoroquinone amine photoinitiator).

It

is

supplied

in

premixed

sheets

having

claylike

consistency. It is provided in opaque tight packages to avoid premature polymerization. The denture base material is adapted to the cast while it is in a plastic state. The denture base can be polymerized without teeth and used as a base plate. The teeth are added to the base with additional material and the anatomy is sculptured while the material is still soft. It is polymerized in a light chamber (curing unit) with blue light of 400-500 nm from high intensity quartz halogen bulbs. The denture is rotated continuously in the chamber to provide uniform exposure to the light source.

Properties of denture resins: Methyl methacrylate monomer:

It

is

clear,

transparent,

volatile

liquid

at

room

temperature. It has a characteristic sweetish odour. The physical properties of monomer are: Melting point Boiling point Density Heat of polymerization Volume shrinkage during polymerization : - 48 0 C : 100.8 0 C : 0.945 gm/ml at 20 0 C : 12.9 Kcal/mol : 21%

Poly (methyl methacrylate): 1. Taste and odour: Completely polymerized acrylic resin is tasteless and odourless. 2. Esthetics: It is a clear transparent resin which can be pigmented (coloured) easily to duplicate the oral

tissues. It is also compatible with dyed synthetic fillers. 3. physical and mechanical properties: Density: The polymer has a density of 1.19 gm/cm 3

Strength: Compressive and tensile strengths: These materials are typically low in strength. However, they have adequate compressive and tensile strength for

complete or partial denture applications.

Compressive strength Tensile strength Hardness: -

75 MP

52 MP

Acrylic resins are materials having low hardness. They can be easily scratched and abraded. Heat cured acrylic resin Self cured acrylic resin Modulus of elasticity: Acrylic resins have sufficient stiffness (modulus of : : 18.20 KHN 16 18 KHN

elasticity 2400 MPa) for use in complete and partial dentures. However, when compared with metal denture bases it is low. Self cured acrylic resins have slightly lower values. 4. Dimensional stability: A well processed acrylic resin denture has good

dimensional stability. The processing shrinkage is balanced by the expansion due to water sorption. a) Shrinkage: Acrylic resins shrink during processing due to two reasons: 1. 2. Thermal shrinkage on cooling Polymerization shrinkage

Polymerization shrinkage:

During

polymerization,

the

density

of

the

monomer

changes from 0.945 gm/cc to 1.19 gm/cc. This results in a shrinkage in the volume of monomer-polymer dough. However, inspite of the high shrinkage, the fit of the denture is not affected because the shrinkage is uniformly distributed over all surfaces of the denture. Thus, the actual linear shrinkage observed is low. Volume shrinkage Linear shrinkage 8% 0.53%

Self cured resins have a lower shrinkage (linear shrinkage 0.26%). b) Water sorption: Acrylic resins absorb water (0.6 mg/cm2) and expand. This partially compensates for its processing shrinkage. This process is reversible. Thus, on drying they lose water and shrink. (However, repeated wetting and drying should be avoided as it may result in warpage of the denture). Solubility: Poly (methyl methacrylate) is virtually insoluble in water and oral fluids. They are soluble in ketones, esters and aromatics and chlorinated hydrocarbons. Alcohol causes crazing in some resins.

6. a.

Thermal properties: Stability to heat: Poly(methyl methacrylate) is chemically stable to heat. It softens at 125 0 C. However, above this temperature i.e., between 125 0 C and 200 0 C it begins to depolymerize. At 450 0 C, 90% of the polymer will

depolymerize to monomer. b. Thermal conductivity: They are poor conductors of heat and electricity. c. Coefficient of thermal expansion: These materials have a high coefficient of thermal expansion (81 x 10 -6 / 0 C).

Addition of fillers reduces the coefficient of expansion. 7. Colour stability: Heat cured acrylic resins have (greater) colour stability. The colour stability of selfcure resins is slightly lower (yellows very slightly). 8. Biocompatibility: completely polymerized acrylic resins are biocompatible.

Pure monomer if inhaled over a long period is toxic. It may also cause allergic manifestations in some individuals.

Precautions to be taken are; i. Minimize residual monomer content by using proper

processing techniques.

ii. iii.

Avoid direct handling of acrylic dough with bare hands. Work in well ventilated areas to avoid inhalation of the monomer vapour and the usage of mouth mask.

Residual monomer: During the polymerization process the amount of residual monomer decreases first rapidly and then later more slowly.

The highest residual monomer level is observed with chemically activated denture base resins at 1% to 4% shortly after processing. When they are processed in less than one hour in boiling water the residual monomer is 1% to 3%. IF they are processed for 7 hours at 70 0 C and then boiled for 3 hours the residual monomer content may be less than 0.4%.

In heat cured acrylic before the start of curing the residual monomer is 26.2%. In 1 hour at 70 0 C it decreased to 6.6% and at 100 0 C it was 0.29%.

In order to reduce the residual monomer in heat cured dentures it should be processed for a longer time in boiling water. The processing temperature should be raised to boiling when most of the polymerization is completed otherwise porosity may result.

9.

Adhesion: The adhesion of acrylic to metal and porcelain is poor, so mechanical retention is required. Adhesion to plastic (denture) teeth is good.

10.

Shelf life: The shelf life varies considerably. The acrylic resins dispensed as powder/liquid have the best shelf life. The gel type has a lower shelf life and has to be stored in a refrigerator.

Porosity Porosity is a processing error in acrylic resins. When porosity is present on the surface, it makes the appearance of denture base unsightly. Proper cleaning of the denture is not possible, so the denture hygiene and thus the oral hygiene suffer. Even when it appears as internal porosity in the form of pores or blebs, it weakens the denture base and the pores are areas of stress concentration, thus the denture warps as the stresses relax. Porosity may be: 1. 2. 1. Internal porosity External porosity Internal porosity: Is in the form of voids or bubbles within the mass of the polymerized acrylic. It is usually not present on

the surface of a denture. It is confined to the thick portions of the denture base and it may not occur equally throughout the affected area. 2. External Porosity: It can occur due to two reasons: i) Lack of homogeneity: If the dough is not

homogenous at the time of polymerization, the portions containing more monomer will shrink more than the adjacent areas. This localized shrinkage results in voids. The resin appears white. It can be avoided or minimized by using proper powder-liquid ratio and mixing it well. The mix is more homogenous in the dough stage, so packing should be done at the dough stage. ii) Lack of adequate pressure: During polymerization or due to lack of dough in the mould during final closure. Bubbles appear which are not spherical and the resin appears white. A pigmented resin appears lighter in colour due to lack of pressure during polymerization.

Crazing Crazing is formation of surface cracks on the denture base resin. These cracks may be microscopic or macroscopic in size.

In some cased it has a hazy or foggy appearance raphe than cracks.

Crazing has a weakening effect on the resin and reduces the esthetic qualities. Cracks formed on crazing are indicative of the beginning of a fracture. Causes: Crazing is due to 1. 2. Mechanical stresses or Attack by a solvent of water

Recent advances: Several modified poly (methyl methacrylate) materials

have been used for denture base applications. These include: Pour type of denture resins, hydrophilic polyacrylates. High impact strength resins, Rapid heat polymerized acrylic and Light-activated denture base material.

High impact strength materials: These materials are butadiene styrene rubber-reinforced poly (methyl methacrylate). The rubber particles are grafted to methylmethacrylate so that they will bond well to the heat polymerized acrylic matrix. These materials are supplied in a

powder-liquid form and are processed in the same way, as other heat-accelerated methyl methacrylate materials.

Rapid heat-polymerized resins: These are hybrid acrylics that are polymerized in boiling water immediately after being packed into a denture flask. After being placed into the boiling water, the water is brought back to a full boil for 20 minutes. After the usual bench cooling to room temperature, the denture is deflasked, trimmed, and polished in the usual manner. The initiator is formulated to allow for rapid polymerization without the porosity that one might expect.

METALLIC DENTURE BASE MATERIALS Chrome castings, gold castings and aluminum castings are still in use. Gold cast bases have some drawbacks. The recent prices are extremely high.

Gold is very heavy when used as a base; of course its accuracy is outstanding and adjustment factor causes no

problems. A maxillary denture with a gold base can be self defeating because of weight.

Chrome

metal

bases

are

economical

to

cast

and

fit

acceptably. They are used as lower full cast lower bases. They are difficult to adjust. Chrome also used to reinforce acrylic denture for added strength and for less dimensional change in denture resin.

Cast aluminum bases are always acceptable they are used as they are easy to adjust with simple burs and rubber wheels. Aluminum can be destroyed by soaking in denture cleansers with chloride ions. They can be used as palatal cover as chrome castings or a full casting veneered with denture resin.

Advantages of metal bases:

Metal base prevents warpage during processing while acrylic resin does not.

Metal base is stronger than acrylic resin and is less subject to breakage.

The fit of metal is more accurate and tissue detail in reproduced more faithfully than acrylic resin bases.

Less tissue change seems to occur metal bases than under those of acrylic resin.

A metal base is less porus than organic material. Metal is a better thermal conductor than organic

material. Dentures made with metal bases show less lateral

deformation in function than do others. Patients appear to master the use of dentures made with metal bases more quickly than do with others. Problems of patients with poor ridges have been treated more successfully with metal bases than others. A snugness of fit, attainable with metal base dentures, seems to be absent in acrylic resin denture bases. Metal denture bases

Metal denture bases may be made from a number of different materials such as gold, aluminum manganese,

platinum, satellite (cobalt-chromium) alloys and stainless steel. Some disadvantages of metal bases are; Greater initial cost and greater restorative cast. Difficulty and expense of rebasing and regrinding

occlusion of metal dentures. Less margin of error permissible in post palatal seal on a metal denture.

Advantages of cast metal bases: The metal base prevents warpage during processing while acrylic resin does not. Metal bases is stronger than acrylic resin and is less subject to breakage. The fit of aluminum is more accurate and tissue detail is more. Less tissue change seems to occur under aluminum or other metal bases than under those of acrylic resin. A metal base is less porus than organic material.

Classification of dental casting alloys:

In 1932, dental materials group at the National Bureau of Standards surveyed the alloys being used and roughly classified them as; Type I Type II Type III Type IV Soft (VHN 50-90) Medium (VHN 90-120) Hard (VHN 120-150) Extrahard (VHN 150)

According to ADA Specification No. 5 a dental casting alloy is classified as; Type I (Soft): For restorations subjected to very slight stress such as inlays. Type II (Medium): For restoration subjected to moderate stress such as inlays. Type III (Hard): For high stress situations, including onlays, crowns, dentures. Type IV (Extra hard): for extremely high stress such as endodontic posts and cores, thin veneer crowns, long span fixed partial dentures and removable partial dentures. thick veneer crowns and short span fixed partial

Desirable qualities of casting alloys: Metal must exhibit biocompatibility.

Ease of melting, casting, brazing (or soldering polishing.

and

Little solidification shrinkage, minimal reactivity with mold material.

Good wear resistance, high strength and sag resistance. Excellent tarnish and corrosion resistance.

Alloys can also be classified as; Alloys for all metal restorations Metal ceramic restorations Removable partial dentures

Alloys for removable partial dentures: Highly noble Noble Au Ag Cu Pd

Ag Pd Au Cu Ag Pd

Base metal

Pure Titanium

Titanium aluminum vanadium Ni-Cr-Mo-Be Ni-Cr-Mo Co-Cr-Mo Co-Cr-W

Requirements of cast metal bases: Bases should be; As thin as possible and at same time rigid depending on alloy used. Dense Accurate that is having a positive fit on master cast without rocking. Of a biologically acceptable alloy.

Design principles of metal bases: Although some aspects of construction of cast metal bases depend entirely on alloy chosen, the principles of design remain essentially the same the design of cast metal base always must be a clinical decision. A mount of coverage, placement of finish lines and type of resin retention used has to be determined. Maxillary bases: Maxillary bases can cover; Only the palate The palate and ridge crest Entire denture bearing area The most satisfactory design covers complete palate and ridge crest, but leaves denture borders in resin. An acceptable

variation in this design also places the posterior palatal seal area in metal and begins resin periphery at pterygomaxillary notch area.

If posterior palatal seal is to be in metal, it is essential that dentist establish this critical area accurately.

Mandibular bases: The mandibular cast base is of only two types; With crest of ridge coverage. With complete coverage of mandibular denture space. Since exact determination and registration of mandibular denture space is difficult clinically. The crest of ridge coverage with resin peripheries is preferable, especially when using chrome base alloys because adjustment and subsequent repolishing are much more difficult than when using resin peripheries. Resin retention: Resin retention for maxillary or mandibular bases is of four types; Raised (relieved) retention mesh. Non-relieved retention of beads. Nail beads Loops.

Since

relieved

retention

places

thin

resin

adjacent

to

denture bearing tissues, it is inferior to non-relieved types which permit a butt joint of thicker resin. In addition non-relieved retention uses less inter-ridge space. GOLD DENTURE BASES Pure gold is a soft and ductile metal and so is not used for casting dental restorations and appliances dental casting golds are alloyed commonly with copper, silver, platinum, palladium, nickel and zinc, alloying with these elements not only improves its physical and mechanical properties but also reduces its cost. Type IV (Extra hard) gold alloys are used for fabrication of removable partial denture frameworks. The composition of type IV gold alloy is; Gold Copper Silver Platinum 69% 10% 12.5% 3.5% 3%

Palladium -

Traces of indium, tin, iron, zinc and gallium function of alloying elements. Gold: Provides tarnish and corrosion resistance and has a desirable appearance it also provides ductility and malleability, it

has low strength. Gold melts at 1064 0 C and has a density of 19.329/cc.

Copper: Is the principal hardener, it reduces melting point and density of gold, it present in sufficient quantity , it gives reddish color, it also helps to age harden alloys in greater amounts it reduces the resistance to tarnish and corrosion of gold alloy. Hence it should not exceed 16%.

Silver: It whitens the alloy, thus helping to counteract the reddish colour of copper to a slight extent it increases harden and strength in large amounts it reduces tarnish resistance. Platinum: It increases the strength and corrosion resistance, it also increases the melting point and has a whitening effect on alloy it helps to reduce grain rise. Palladium: It is similar to platinum in its effect, it hardens as well as whitens alloy it also raises the fusion temperature and provides tarnish resistance it is less expensive than platinum thus reducing the cost. Trace elements: Zinc: It acts as a scavenger for oxygen without zinc the silver in the alloy causes absorption of oxygen during melting. Later

during

solidification,

the

oxygen

is

rejected

producing

gas

porosities in the casting.

Indium tin and iron: They help to harden the metal ceramic gold-palladium alloys, iron being the most effective.

Gallium: It is added to compensate for the decreased coefficient of thermal expansion that results when the alloy is made silver free. The elimination of silver reduces the tendency for green stain at the margin of metal porcelain interface.

Iridium, ruthenium, rhenium: They help to decrease the grain size they are added in very small quantities. Desirable properties in a gold base dentures: It has weight which is very important in retention of lower

denture. It has the closest possible adaptation to underlying

tissues. Since it is cast directly to a refractory duplicate cast. It provides bracing which prevents the acrylic resin from

contracting in horizontal dimension during processing and ensures better over all adaptation of denture base. It is kind to underlying tissue because of excellent

tolerance of tissues to gold.

Chrome cobalt alloy bases in comparison with gold: Chrome cobalt alloys cannot be cast to same degree of accuracy. Being lighter, the base has to be cast to such a thickness to obtain desired weight that it might interfere with proper tooth placement in some degrees. Cobalt chromium alloys are so hard that they are difficult to adjust. A cobalt-chrome alloy framework is wholly covered by acrylic resin is a highly desirable adjust to any lower denture. If desired weight cannot be obtained excessive bulk section of tungsten rods can be spot welded to frame or at points of least interference. Characteristics of gold bone lower dentures: Gold bases was thin and appeared to be utilized primarily to provide good tissue adaptation. Should not employed for a patient having appreciable undercuts existing in lower ridge. Weight and bracing are most important factors provided by lower gold base close tissue adaptation and tissue tolerance are secondary. Possible relining.

To fulfill above requirements, gold base should; Cover as much of basal surface of lower denture as possible and still allow at least 3 mm of acrylic resin around the entire border. Cover about one half of retromolar pad. Should have enough finger like extension into denture to insure good retention of acrylic. Be cast in a hard, partial denture type of gold.

Extent of gold base: Gold base should not be extended into undercut as it may require trimming of final cast to seat the casting. Gold base extension in cast of undercut height of contour should be marked with pencil held vertically, if tip of pencil touches the cast beyond undercut and is outside the border extension then undercut should not be

covered. It tip of pencil touches the cast beyond the undercut and is inside the border extension, then undercut can be covered by gold. This is permissible because the casting will contact the cast firmly beyond the area trimmed and prevent the acrylic resin

from

flowing

under

the

casting

and

displacing

it

during

processing.

Indications of cast gold base: Can be used in all types of edentulous mandibular ridges, it is especially indicated for patients who has a resorbed residual ridge and has worn small under-extended dentures. This is because the tendency of lip and cheek to return to their habitual position will result in vertical displacement of the usual light weight lower denture. This tendency will not result in

displacement of a gold base denture because of its added weight.

Contraindications of lower gold base dentures: Lower gold bases are not indicated for dentures for very old patients who have suffered a great loss of muscle tone and have no residual ridge. These patients are often stooped and head in a forwardly inclined position. In these patients weighted lower denture slides forward on body of mandible, and lower lip is too weak to hold it in place, the result is a constant protrusion and soreness of oral surface of lower lip. Patients who fear of oral cancer, these patients will not permit the use of gold base for fear the hard metal would cause cancer.

 Some patients have a fixed idea that even a denture with a plastic base is too heavy. Such patients cannot tolerate the added weight of gold base.

Weight of the base: Gold bases varies in weight from10 to 24 dwt. According to clinical results the weight should be between 12 to 20 dwt. A weight of 16 dwt was considered to be ideal.

Weight of denture base and vertical dimension of rest position: According to clinical analysis, the vertical dimension

established at rest will be increased by about 1.5 mm after 30 days of insertion of denture with gold base.

Relining: Gold base lower dentures can be relined satisfactorily providing there is sufficient extension of acrylic resin beyond the gold around the border.

Comparison of weight of gold and weight of lost tissue (teeth and bone): The weight of teeth and bone lost through extraction and extensive resorption will be around 29 dwt and 23 grains. The

weight of lower denture with porcelain teeth and gold base is 16 dwt. Summary: Most lower dentures weigh less than half as much as the teeth and supporting tissues have been lost. This reduction in weight might contribute to improper muscle function and a reduction in normal rest V.D. This is an important factor in adequate extension and retention of lower dentures. These deficiencies can be overcomed by a cast gold lower denture base and adequate expansion of the bone.

ALUMINUM DENTURE BASES First casting of aluminum complete denture base by Bean (US). Few years later Caroll presented a method for casting the aluminum bases under pressure. Advantages: Thermal conductivity, malleability and rigidity. Disadvantages: Warpage and imperfect density of casting.

Review Campbell Aluminum is best base upon which a denture can be fabricated. Because of thermal conductivity it provides favorable patient response and also promotes a normal pink, physiologic condition of mouth. Sizeland-Coe First to discuss of super-pure base. aluminum Purity of alloy newer for alloy

construction

denture

eliminated much of intraoral corrosion that existed with earlier alloy. Anodizing aluminum alloy: This process adds an oxide layer to surface of alloy which helps to prevent tarnish and corrosion and it enables the aluminum to be colored as desired. This process is called as Alumilite process. Alumilite process was recommended by the aluminum company of America (ALCOA). Alumilite gives maximum corrosion resistance. Granger Recommended use of metal bases particularly aluminum. According to him they provide greater surface detail and more accurate fit which causes both stability and retention of his bases.

Neill

Compared physical properties of aluminum with other alloys. Properties Density Hardness (Brinell) Ultimate strength Melting range % of elongation tensile Aluminum alloy 2.66 60.68 9.6 580.640 4 Acrylic resin 1.18 23.29 3 Chrome cobalt 8.2-8.6 280 49 Gold alloy 15 Soft-138 Hard -210 Soft-26 Hard -49 1270-1305 870-985 5 Soft-4.25 Hard -1-6 Landquist: In region of midpalatine

Average discrepancy 0.020 inch for heat cured resin under light pressure. - 0.0039 inch for aluminum bases. Primary disadvantage: Grayish discoloration rather than shiny silver finish may be due to inadequate cleaning. Barosoum et al. Accuracy of aluminum is better than cold cure and heat cure resin and hence they will be less irritating and provide tissue health. Swartz: Compared the retention of various bases (One hook in mid-palatal region). Aluminum (most retentive 15.46 pounds)

Porcelain (13.24 pounds) Cold cure acrylic resin (12.89 pounds) Heat cured acrylic resin (least retentive 12.26 pounds) Defurio and Gehl retention of various bases (Seven hooks in

Compared

periphery of base as well as in mid-palatal region). Aluminum, acrylic resin, gold and chrome cobalt alloy. Chrome degree). Aluminum second in retentive ability. Regli and Kydol Lateral deformation in horizontal plane gold metal base with 28 gauge 8.5 times more resistance to lateral deformation than acrylic resins. Jha cobalt alloy resisted displacement to greatest

Tissue response of aluminum bases; After 8 weeks - Decrease in thickness of stratumcorneum. No connective tissue changes. Mild increase in vascularity and fibrosis along with small number of chronic inflammatory cells. Technical considerations:

Several techniques can be used for making aluminum denture bases depending on the impression method, duplication method and counting procedures utilized.

One of main reasons for using cast aluminum alloy as a denture base material is its accurate fit. Therefore impression techniques should be one which accurately records tissue detail and has as great a tissue coverage as possible.

The problems most frequently encountered are pitting and porosity of aluminum casting. These are largely due to passivity of aluminum because of aluminums affinity for oxygen, it oxidizes rapidly in air to form a strong adherent oxide layer at higher temperatures, oxidation occurs much more rapidly, if the alloy is overheated during casting, or if it is heated for a longer period of time than necessary, an excessive amount of oxygen is incorporated into molten alloy, upon solidification, oxygen is retained, resulting in pitting and porosity.

COBALT CHROMIUM ALLOYS Cobalt chromium alloys have been available since 1920s. These alloys are hard, rigid and corrosion resistant. Because of their corrosion resistance at high temperature they are also used

for car sparking plugs and turbine blades. They are also known as Stellites because they maintain their shiny, star-like

appearance under different conditions.

Composition: Cobalt Chromium Nickel Molybdenum Carbon upto 35-65% 20-35% 0-30% 0-7% 0.4%

Tungsten, manganese, silicon and iron may also be present in small quantities. Effect of constituents: Cobalt: Principal element, cobalt is hard, strong and rigid metal high melting point. Chromium: Forms a solid solution with cobalt it renders the alloy corrosion resistant, due to a passivating effect. Chromium

content is directly proportional to tarnish and corrosion resistant, it reduces melting point.

Nickel:

It

replaces

some

of

cobalt-nickel

and

cobalt

are

interchangeable, it decreases hardness, strength, MOE and fusion temperature, increases ductility. Molybdenum, tungsten,

manganese

and

silicon

harden

and

strengthen

the

alloy.

Molybdenum reduces the grain size.

Manganese and silicon primarily act as oxide scavengers and prevent oxidation of other metals during melting. They also function as hardners.

Carbon: It is invariably present and it reacts with many of other metals or constituents to form carbides. These solidify lost during cooling after casting, so appear at grain boundaries, the carbon content of cobalt chromium depends on; The quantity of carbon initially present before casting and Pick-up carbon from a heating flame, if this technique of melting is used.

Control of carbon content of these alloys is most important. The carboides that are formed embrittle the alloy with the consequent danger of for example, partial denture clasp fracture.

Properties: Cobalt-chromium alloys have replaced type IV gold alloys because of their lower cast and adequate mechanical properties.

Chromium is added for tarnish resistance since chromic oxide forms an adherent and resistant surface layer.

Physical properties: Density: The density is half that of gold alloys, so they are lighter in at 8 to 9 gms/cm 2 .

Fusion temperature: The casting temperature of this alloy is considerably higher than that of gold alloys 1250 0 C to 1480 0 C.

ADA specification No. 14 divides it into two types based on fusion temperature, which is defined as liquidus temperature.

Type

(High

fusing):

Liquidus

temperature

greater

than

1300 0 C. Type II (Low fusing): Liquidus temperature not greater than 1300 0 C. Technical properties: Yield strength: It is higher than that of gold alloys 710 MPa. Elongation: Their ductility is lower than that of gold alloys depending on compression rate of cooling and the fusion and mold temperature employed it ranges from 1 to 12%.

These alloys work harden easily so care must be taken while adjusting clasp arms of partial denture. Modulus of elasticity: They are twice as stiff as gold alloys. Thus, casting can be made more thinner, thus decreasing the weight of RPD adjustment of clasp is not easy 225 X 10 3 MPa. Hardness: These alloys are 50% harder than gold alloys. Thus cutting grinding and finishing is difficult. Tarnish and corrosion: Formation of a layer of chromium oxide on surface of these alloys prevents tarnish and corrosion in oral cavity. This is called Passive effect. Solutions of hypochlorite and other chlorine containing compounds that are present in some denture cleansing agents will cause corrosion in such base metal alloys. Even the

oxygenating denture cleansers will stain such alloys. Therefore, these solutions should not be used for cleaning chromium base alloys. Casting shrinkage: Casting shrinkage is much greater than that of gold alloys, so limited use in crown and bridge 23%. High shrinkage is due to their high fusion temperature.

Porosity: As in gold alloys, porosity is due to shrinkage and release of dissolved gasses. Porosity is affected by compression of alloy and its manipulation.

Comparison with gold alloys:

Ultimate Materials Condition MOE GN/m 2 95 100 250 Proportiona tensile l limit 360 585 515 strength MN/m 2 480 790 690 Elongatio n 15 10 4 Hardness M.R. Density

Gold alloy type IV Gold alloy type IV Cobalt chromium alloy Silver palladium alloy

Soft Hard As Cast

130150 210230 370

850950 210230 370

15 15 8

Soft

95

345

480

140170

950105 0

12

The proportional limit of cobalt-chromium alloys is less than that of the hardened gold alloys, and the ultimate tensile strength of former is slightly lower than that of latter material.

The cobalt-chromium alloys have a modulus of elasticity about twice that of gold alloys that is they are stiffer. This is very desirable for connectors and it means the sections of cobalt chromium alloys of about half the thickness of gold alloys can be used to achieve that same

degree of rigidity. Gold alloy clasps, however, are more flexible and can be withdrawn over a greater degree of undercut than clasps of cobalt chromium. Cobalt chromium alloys are more brittle (lower

percentage elongation). Higher melting range and greater hardness of cobalt chromium alloys. Casting shrinkage of cobalt-chromium alloys is greater than that of gold containing materials but the available investment materials appear to give satisfactory

compensation for this contraction. The density of cobalt-chromium is about half that of gold. This together with fact that cobalt-chromium dentures can be made of thinner cross section.

Manipulation: The casting technique for these alloys is similar to that of gold alloys, but the following differences in manipulation should be noted. The melting point of these alloys is on range of 1250 0 C 1450 0 C, hence gypsum bonded investment should not be used. A silica bonded or phosphate bonded material should be chosen.

Because of high melting range, gas/air torches cannot raise the alloy temperature sufficiently to melt it. There is a choice of using either.

Oxy-acetylene flame: This requires careful control use the correct ratio of oxygen to acetylene. Too much of the former gas may result in oxidation of alloy: too much acetylene will result in carbon pick-up by alloy which must be avoided.

Induction heating, where the alloy is heated electrically. This method is usually preferred, as it avoids the problems mentioned above. Because of great hardness of alloy special polishing and finishing techniques are required. Sand blasting is used to smooth the surface of casting and remove adherent investment materials. Electrolytic polishing is then applied the principle is the same as for electroplating, except that the appliance is made the anode of on electrolytic cell. When a current is applied the surface layer is dissolved.

STAINLESS STEEL DENTURE BASE

Stainless steel has been occasionally used or a denture base material since about 1921. of particular importance is the 18/8 austenitic type material.

Composition: Steel is an alloy of iron and carbon, with upto 2% carbon alloys with greater quantities of iron are cast iron or pig iron.

Chromium may be added in (12-30%) small quantities to improve tarnish resistance. When chromium is added the alloy is called as stainless steel. Other than chromium it may also contain other elements such as nickel which also helps in corrosion resistance and strength of alloy.

Passivating effect: Stainless steels are resistant to tarnish and corrosion, because of passivating effect of chromium, a thin, transparent but tough and impervious oxide layer forms on surface of alloy when it is subjected to an oxidizing atmosphere (air), which protects against tarnish and corrosion, it loses its protection if the oxide layer is ruptured by mechanical or chemical factors.

Conventional method of swaging:

A stainless steel sheet is pressed between a die and a counter die in a hydraulic press. Dies and counter-dies are mode of low fusing alloys, such as zinc, copper-magnesium-aluminum, tin-antimony-copper, lead antimony tin and lead bismuth alloys. Some problems associated with this conventional swaging procedure are; Possible dimensional in accuracy, particularly if

contraction of die metal or alloy is not matched by expansion of model. Loss of fine detail, since many stages are involved between recording the original impression and obtaining the final product. Dies and counter dies can be damaged under hydraulic pressure. It was usually customary to use more than one die and counter-die. It was difficult to ensure a uniform thickness of finished plate. Uneven pressure on die and counter die could cause wrinkling of steel.

Properties: Despite difficulties in swaging mentioned above, stainless steel has some merit as a denture base material.

Very thin denture base can be produced. Figures of as low as 0.11 mm have been quoted compared to about 1.52 mm of acrylic denture.

Steel is fracture resistant. Such dentures are not heavy, because of the thinness of material, and the fact that the density of steel is not high compared to some other metallic materials.

The corrosion resistance is good. The thermal conductivity of stainless steel is such that the sensation of temperature is rapidly transmitted to the palate. This is an advantage not shared by polymeric denture base materials.

Newer methods of swaging: To overcome problems with previous method newer

methods of swaging have been investigated.

Explosion forming: A die made using an epoxy resin is prepared from the dental impression. A stainless steel plate is placed on top of the die, with a layer of plasticine on it. A pressure wave is produced by a small charge of high explosives. The pressure is transmitted through plasticine on to the steel, forcing it into required shape.

Explosion hydraulic forming: This is similar to the above, except that water is used as medium for transmitting pressure wave. Hydraulic forming: The apparatus for this technique is as follows;

A die is placed in a metal cone and located in pressure vessel.

A sheet of stainless steel of required thickness is placed in position over the die.

A rubber diaphragm is placed over the stainless steel, and a cover plate inserted in place and held in position by high tensile bolts.

Oil is pumped into chamber upto a pressure of around 70mn/M 2 .

After the pressure has been released, the chamber is opened and the work-piece is removed and cleaned.

The denture base is cut to size, and retentive tags are resistance welded into position.

After polishing denture, it can, it necessary be reformed on the die to eliminate distortion that may have occurred during welding.

The stainless steel can be annealed by heating at 1050 0 C for two minutes, followed by quenching in water. TITANIUM AND TITANIUM ALLOYS

Features: Resistant to electrochemical degradation. Stable oxide layer Repassivating effect

Biocompatibility Low weight, low density, low MOE and high strength.

Characteristics of titanium: Titanium is attractive for its low-weight to volume. High strength to weight. Fatigue resistance Corrosion resistance Biocompatibility: Titanium is hypoallergic and posses many of clinically favorable properties of type III and IV dental gold alloys

Casting requirements of titanium: Melting point of pure titanium is 1720 0 C and is usually achieved by electric arc. Melting method not used in dentistry. Molten titanium such is as extremely nitrogen reactive oxygen with and other with

elements

and

compounds such as silica used in casting investments. When cooling from a molten state, titanium crystallizes in an alpha phase below 883 0 C. Alpha phase mechanical properties are similar to those of type III and IV dental gold alloys. Above occurs the in critical -phase 883 0 C temperature, by crystallization and

characterized

brittleness

increased strength. Titanium light weight presents another formidable

obstacle for common centrifugal force casting methods. Atomic weight of titanium is 47.90 making it one half as heavy as nickel chromium alloys and one fourth as heavy as high gold alloys.

Two systems for casting of titanium:

One

system

uses

centrifugal

force

generated

by

powerful motor wound spring and an argon gas melting and casting environment. Other system uses a vacuum/pressure casting machine with electric arc melting in an argon gas environment.

TEMPORARY DENTURE BASE MATERIALS Elder (1955) gave the following requirement of temporary denture base. The temporary denture base should adopt to basal seat area as finished denture. The temporary denture base should have the same border form as the finished denture base. The temporary denture base should be sufficiently rigid to resist biting forces. The temporary denture base should be dimensionally stable. The baseplate as constructed should permit its use as a base for setting up teeth. It should be possible to construct baseplate quickly, easily and inexpensively. Baseplate should have no undesirable color.

(Tucker, 1966) baseplate should not abrade the cast during removal and replacement.

Shellae recording base material: Shellae is a commonly used material for recording bases. It is supplied commercially in forms shaped to correspond to general shapes of maxillary and mandibular arches. It is

inexpensive and can be easily and quickly adapted accurately, strengthened and handled carefully. It can be effectively utilized both for maxillary and mandibular recording bases, if not

adequately strengthened, shellac tends to warp when subjected to repeated changes in temperature being a brittle material it is also subjected to breakage. Wires of 12 to 14 gauge should be used to increase strength and rigidity and thus reduce distortion of shellac bases. For the maxillary cast, the wire is placed across the posterior palatal seal area, while for the mandibular cast it is adapted within lingual flange. This material is similar to the one used for special tray construction but is thinner, generally pink in color and contains no filler. Shellac is more stable than wax at mouth temperature but is more difficult to adjust at the chairside.

Shellac is a thermoplastic material supplied in shapes suitable for upper and lower arch forms. Some materials contain on aluminum powder which is said to increase the strength and decrease the brittleness of shellac. Composition: Shellac derived from resinous exudate of scale insect, is the base of this base plate material. Other materials such as powdered talc or mica, serve or fillers and increase the strength. Properties: Shellac baseplate will adapt to intimate contact with cast, they often warp when rewarmed as a result of release of stresses baseplates of shellac, a thermoplastic material, also warps when warm wax is added while forming the occlusion rim and setting denture teeth. Advantage: The principal advantage of shellac baseplate is minimal amount of time required to adopt and make them.

Disadvantage: The main disadvantage is the chance of losing initial adaptation, but it is equally true that shellac baseplates readily readapt.

METHODS: 1 st method: Shellac should finish just below the crest of ridge and at the junction of hard and soft palate. This position is drawn on cast which is then dusted lightly with French chalk to prevent shellac sticking to it. Shellac is softened and adopted to palate care should be taken to prevent thinning Its periphery is resoftened and trimmed to a general shape by use of scissors. Final shaping is accomplished by use of a file, the edge of shellac being chamfered to blend into the ridge. It may need further heating and adaptation before edges are smoothened with sand

paper. Retentive form for attachment of rim is made by roughening the shellac with a hot wax knife in the form of a 5 mm wide band and coating it lightly with sticky wax. A strip of modeling wax, the length of sulcus area, is softened and adapted to sulcus. Outer surface of alveolar ridge and on roughened area of shellac. It is sealed to shellac by use of a wax hot knife. Muscle attachments are relieved and fitting surface of bone checked for accuracy of detail.

2 nd method: All undercuts must be blocked out prior to adapting the base. Wet asbestos is recommended, since shellac requires heat to soften and this heat could distort wax and other plastic materials. Cast should be dusted with talcum powder or soaked in water for a short period of time until the surface of cast is moist. As an alternative, tin foil (0.001 inch) can be adapted to the cast. Using a Bunsen flame shellac is first adapted on palatal or lingual side than on the ridge crest and later on the buccal side firm pressure is applied with wet fingers or wet cotton to accurately adapt the shellac to cast. While material is still warm and soft, it is removed from the cast and trimmed with scissors. Leaving approximately 5 mm beyond the edge of the cast, the shellac is repositioned and reheated and then carefully readapted the trimmed edges are heated using a hanau torch, elevated from the cast, and folded into themselves, and burnished with No. 7 wax spatula to form a smooth, rounded border.

Care

must

be

taken

not

to

overheat

the

shellac.

Overheating will cause the molten shellac to penetrate the pores of stone and adhere to surface of cast on coding attempts to remove the shellac base can result in a fracture of cast surface.

Bubbling or smoothing of shellac indicates overheating, the shellac also turns black if overheated and is esthetically

unacceptable.

Stabilized shellac baseplates: As shellac baseplate tends to undergo warpage. Many materials were recommended for stabilizing them. They were; ZOE impression paste Elastomeric impression material Autopolymerizing resin

Baseplate stabilized with ZnOE impression paste: Shellac baseplates reinforced with ZnOE paste exhibit better adaptation and dimensional stability. This adapts well to the cast and can improve the dimensional stability of shellac baseplate. Their disadvantages are that the baseplates are thicker because of the thickness of impression paste liner, their

construction requires additional time, and block out of undercuts on cast is essential as rigid, stabilized baseplates cannot extend into undercuts. Baseplate materials: stabilized with elastomeric impression

The advantages of using these materials as stabilizers are their inherent flexibility and smooth surfaces. The flexibility of material permits baseplate extensions into moderate undercuts and minimizes the need for blockout of cast. The principal disadvantage of this procedure is added thickness of baseplate and it costs more because of materials and increase in

construction time.

Baseplate stabilized with autopolymerizing resin: Autopolymerizing resin improves both adaptation and

rigidity of baseplate. The disadvantages of this method are possibility of warping baseplate as a result of internal stresses being released in resin liner and additional time required for fabrication. Baseplate wax: Baseplate wax recording bases are inexpensive, easily formed and esthetic. But they lack rigidity, dimensional stability and can easily be distorted. A strengthening wire adapted in posterior palatal seal area of maxillary base or incorporated into lingual flange of mandibular bore will increase both rigidity of mandibular bone will increase both rigidity and the resistance to distortion. Talcum powder is applied to cast to prevent wax stiching to the cast. As an alternative, the cast may be increased

in water for a short period until moist, the wax is softened over a Bunsen flame and adapted. Excess wax is removed with a sharp instrument and borders rounded and smoothed.

Impression compound base: Impression compound may be used as an alternative to shellac but it is normal to confine its use to cases where the rim is to be of the same material. It is reasonably stable at mouth temperature and can be adjusted at the chairside by use of a warm wax knife.

Impression compound is softened in a water bath at a temperature of 60 0 C and flattened into an arch form about 1.5 mm thick and large enough to cover the whole cast. It is resoftened and adapted to the cast as described for wax bases. The edge may be resoftened in water or over a Bunsen burner flame to allow for trimming a file is used for final trimming. Impression compound is easily thinned and distorted during construction of the base but is reasonably stable once shaped.

Reference: *

CONTENT