Die Materials, Investment and Inlay Wax

Good morning
Die, Inlay Wax And Investment
CONTENTS
Introduction
Die materials
What is a Die
Ideal requisites for die materials
Types of die materials
Properties of each die material
Techniques of die fabrication
Compatibility of die material with impression materials.
Inlay wax
CONTENTS
Ideal requisites of inlay wax

Composition
Classification
Properties
Fabrication of wax pattern
Distortion of wax pattern and prevention
CONTENTS
Investment materials
What is an investment
Components of an investment material
Types of investment materials
Indications of each investment materials
INTRODUCTION
Direct
restorations are usually not feasible and advisable in teeth
where more than half the tooth structure is lost.

In
such scenarios the indirect restorations come into play
They
provide the requisite resistance and retention form as well
support the remaining tooth structure.

The
indirect restorations are also indicated as treatment options
over direct restorations in conditions where the anatomical

contours and embrasures are to be modified.
INTRODUCTION
The
casting method for fabrication the indirect
restorations basically consists of:
Accurate reproduction of the prepared tooth, its

relation with adjacent teeth and supporting tissues,
Forming a wax pattern,
Surrounding it with a suitable investment material,
Heating the investment mold to remove the wax
A, Impression.
B, Cast. C, Wax pattern on die. D, The pattern is attached with
Finally
casting the molten metal into the mold.
sprue to a rubber crucible former and invested. E, Casting. F, Luted restoration.
DIE
MATERIALS
INTRODUCTION
During
fabrication of indirect restorations, accurate
reproduction of the tooth, its relation with adjacent teeth

and supporting tissues is essential.
This
is where the role of a die comes into play.
DEFINITIONS
It
is the positive reproduction of the form of the prepared
tooth in any suitable substance.
The
(GPT 7)
die is a positive reproduction of the prepared tooth
and consists of a suitable hard substance of sufficient

accuracy usually an improved stone, resin or metal.
(Rosenstiel et.al)
DEFINITIONS
A
reproduction of a prepared tooth made from a gypsum
product, epoxy resin, a metal or a refractory material.

(Anusavice 11th edition )
The
die is a model of the individual prepared tooth on
which the margins of the wax patterns are finished.

(Schillingburg)
IDEAL REQUIREMENTS OF A DIE MATERIAL

They
should accurately reproduce all the details in the
impression.
They
The
should be dimensionally stable.
die should have a smooth surface and the ability to
resist abrasion.
They should be compatible with impression materials

and there should be no interaction between the surface of
the impression and cast or die.

The
die should have toughness to resist breakage during
fabrication or burnishing of fine edges.

Colour
of the die should be in contrast to the colour of
wax. This helps to facilitate the manipulative procedures

that will be carried out.
It
should be reasonably easy to use without excessive
manipulative procedures.

It
should be relatively inexpensive.
Should
It
be compatible with separating agent used.
should be easily wettable by the wax.
TYPES OF DIE MATERIALS

A
wide variety of materials have been used for the
fabrication of the dies. They may be broadly classified as

follows:
GYPSUM
PRODUCTS:
Dental stone Type 4, high strength.

Dental stone Type 5, high strength high expansion.
METALS:
o Electroformed
o Sprayed
metal
o Amalgam
dies
or electroplated dies.

POLYMERS:
o Metal
filled resins or inorganic filled resins.
o Polyester
o Epoxy
resins
resins.
CEMENTS:
Silico phosphate
CERAMIC
o For
OR REFRACTORY DIE MATERIALS:
direct
fabrication
of
preparation of wax patterns.
porcelain
crowns
or
Selection of the type of die material usually depends on:

The
impression material used.
Purpose
Time
for which the cast or die is used.
factor involved.
Materials
that will be manipulated on the cast or die.
GYPSUM PRODUCTS
According
to ADA specification No. 25 the gypsum
products are classified as follows :
Type I Impression plaster
Type II Model plaster
Type III Dental stone
Type IV Dental stone, high strength
Type V Dental stone, high strength and high

expansion
GYPSUM PRODUCTS
PRODUCTION OF GYPSUM PRODUCTS :
Plaster and stone products are produced by calcining calcium

sulphate dihydrate or gypsum.
Gypsum is ground and subjected to temperatures of 110 0 to

1200c to drive off part of the water of crystallization and is
converted to calcium sulphate hemihydrate [ CaSO4.1/2 H2O ].
1100-1300c
CaSO4.2H2O
Calcium sulphate
Dihydrate
CaSO4.1/2 H2O
Calcium sulphate
hemihydrate
GYPSUM PRODUCTS
PRODUCTION OF GYPSUM PRODUCTS :
Depending on the method of calcinations, different forms of the

hemihydrate can be obtained They are :
-hemihydrate
hemihydrate
-modified hemihydrate
The
alpha modified hemihydrate is made by boiling gypsum in a
30% aqueous solution of calcium chloride & magnesium chloride
GYPSUM PRODUCTS
SETTING REACTION
(CaSO4)2 . H2O + 3 H2O
Theories
2 CaSO4 . 2 H2O + unreacted (CaSO4)2 . 1/2 H2O + heat
regarding the setting reaction
Colloidal
theory
Hydration
theory
Dissolution
Precipitation theory
Based on dissolution of plaster and instant recrystalization of

gypsum, followed by interlocking of the crystals to form the set solid
GYPSUM PRODUCTS
Manufacture of Type IV Dental Stone and Type V Dental Stone
Types
4 and 5 high-strength dental stones are manufactured
with a high-density raw material called densite.

This
variety is made by boiling gypsum rock in a 30% calcium
chloride solution, after which the chloride is washed away with

hot water (100 C) and the material is ground to the desired
fineness.
TYPE IV STONE WHIP MIX
TYPE V STONE
GYPSUM PRODUCTS
Type IV Dental Stone
These
are high strength dental stone.
W: P ratio
0.22 -0.24
Setting time
12 4 minutes
Setting expansion
0.10%
Compressive strength
5000 psi
Hardness
92 RHN
GYPSUM PRODUCTS
Type V Dental Stone :
These
are high strength, high expansion dental stones.
W: P ratio
0.18 -0.22
Setting
time
12 4 minutes
Setting
expansion
0.30%
7000 psi
Compressive
strength
GYPSUM PRODUCTS
Type V Dental Stone
The
Type V dental stone gypsum product exhibits a higher
compressive strength than does the type IV dental stone.

In
addition setting expansion has been increased from a
maximum of 0.10% to 0.30%.

This
is because certain newer alloys such as base metal alloys
have a greater casting shrinkage than noble metal alloys. Thus

higher expansion is required in the stone used for the die to aid
in compensating for the alloy solidification shrinkage.
GYPSUM PRODUCTSx
Advantages of Type IV & Type V Stones
They are relatively inexpensive
Easy to use
Compatible with all impression material.
Good surface detail reproduction (capable of reproducing a
20m-wide line as prescribed by A.D.A specification No.19).
Disadvantages of gypsum dies
Susceptibility to abrasion during carving of wax pattern.
GYPSUM PRODUCTS
Gypsum dies are sometimes modified to:
To make them more abrasion-resistant
To change the dimensions of the dies.
To increase the refractoriness of the dies.
To produce a combination of these effects.
GYPSUM PRODUCTS
Several means are used to increase the abrasion resistance
Electoplating,
Coating the surface with cyanoacrylate
Adding a die hardener to the gypsum
However each of these methods may increase the die

dimensions slightly thus reducing accuracy.
GYPSUM PRODUCTS
Die hardener
Mixing
high-strength dental stone with a commercial hardening
solution containing colloidal silica (about 30%) improves the

surface hardness of the set gypsum.
Cyanoacrylate
or acrylic resin(polystrene) can be applied to the
finish line area of a die to prevent abrasion by waxing instruments

during fabrication of the wax pattern.
The
thickness of the cyanoacrylates at the finish line can range
from 1-25m while acrylic lacquers can add 4-10m of thickness.
GYPSUM PRODUCTS
Special gypsum products ;
Since 1991, a plethora of new dental stones have been introduced
One
type is extremely fast- setting and ready to use in 5min,but
it has little working time

Another
product changes color to help denote when it is ready
for use.
Most
recently another trend is the addition of a small amount of
plastic or resin, which reduces brittleness and improves

resistance to abrasion during the carving of wax patterns.
GYPSUM PRODUCTS
DIE STONE INVESTMENT COMBINATION
A commercial gypsum- bonded material called divestment is
mixed with a colloidal silica liquid.
The die is made from this mix, and the wax pattern is than
constructed on it then the entire assembly [die and pattern] is
invested in a mixture of divestment and water thereby
eliminating the possibility of distortion of the pattern on removal
from the die or during the setting of the investment.
GYPSUM PRODUCTS
DIE STONE INVESTMENT COMBINATION
Divestment
is
gypsum-
bonded
material
it
is
not
recommended for high-fusing alloys that are used for metalceramic restorations but it is a technique of choice for use
with conventional gold alloys especially for extra coronal
preparations.
Divestment
phosphate recommended for high fusing alloys.
Type 1: For casting inlays and crowns
Type 2: For casting complete and partial denture bases
GYPSUM PRODUCTS
Die spacer :
An
agent applied to a die to provide space for the luting agent in
the finished casting

Types
of die spacers :
Resins
Model paint
Coloured nail polish
GYPSUM PRODUCTS
METHODS OF APPLICATION OF DIE SPACER
Paint
on technique
Spray
Pen
Ideal
technique
technique
die spacer thickness is 25 microns
Spacers
are applied within 0.5mm of the preparation finish line
to provide relief for the cement luting agent
ELECTROFORMED DIES
Electroplating
the dies can be used to overcome the poor
abrasion resistance of gypsum

The
electroplated dies have moderately high strength, adequate
hardness and excellent abrasion resistance.

Detail
reproduction of a line 4m or less is readily attainable on
an electroplated die when an nonaqueous elastomeric impression

material is used.
ELECTROFORMED DIES
Advantages
High strength,
Hardness
Abrasion resistance.
ELECTROFORMED DIES
The first step in the procedure is to treat the surface of the

impression material so that it conducts electricity. This process is
referred to as METALLIZING.
In this process, a thin layer of metal, such as silver is deposited

on the surface of the impression material.
Conductive silver lacquer for nonconductive

surfaces, e.g. silicone impressions, for copper
plating of working models.
ELECTROFORMED DIES
Requirements for electroplating
The
impression to be coated is made the cathode.
Anode
is the metal to be deposited either silver or copper
Anode
and cathode holder.
Electrolyte
:- the solution through which the electric current is
passed.
Ammeter
:- the current passed is of 10mA / tooth area for 12 hrs.

It should not exceed 50mA.
Plating
tank glass or hard rubber with well fitting cover to

prevent evaporation.
ELECTROFORMED DIES
Copper plating
The
surface of the impression is rendered conductive by coating
it with fine particles of copper or graphite.

The
coated impression is made the cathode (negative electrode)
of a plating bath, with an anode (positive electrode) of copper.

The
electrolyte is an acid solution of copper sulfate (about
250g/l).
ELECTROFORMED DIES
Copper plating
A
current is passed, causing slow dissolution of the anode and
movement of copper ions from anode to cathode, thus plating the

impression
Dental
stone is then cast into the plated impression.
ELECTROFORMED DIES
Silver plating
Polysulfide and silicone impression materials can be silver plated
by the same general technique except
1)
The impression is coated with silver or graphite powder.
2)
The anode is silver.
3)
The electrolyte is an alkaline solution of silver cyanide
An anode of at least twice the size of the area to be plated, should

be employed, and the electroplating is carried out approximately 10
hr, using 5 to 10 mA.
ELECTROFORMED DIES
Problems in Electroplating
Variable
degrees of distortion commonly occur and hence the
technique must be performed slowly.

The
time required to produce a cohesive film of metal(typically 8
hrs) is ample for the development of dimensional changes in the

impression.
Not
all the impression materials are suitable for plating because
of their low surface energies, silicone impression materials are

difficult to electroplate evenly.
ELECTROFORMED DIES
Problems in Electroplating
Polyether
impressions because of their hydrophilic nature imbibe
water & become distorted. Therefore they cannot be plated

accurately.
Poly
sulfide polymers can be silver plated but it is difficult to
copper plate them

Drawback
of silver plating is the use of a cyanide solution,
which requires special precautions because of its extreme

toxicity.
EPOXY RESIN DIES

Resins
are used as die materials to overcome the low strength
and abrasion resistance of die stones. Most available resin die

material is epoxy resin but polyurethane is also used.
The
fast setting epoxy hardens rapidly so that dies can be waxed
up in half an hour after injecting into the impression
The epoxy resin is in one cartridge and the catalyst is in the other. Forcing the two pastes
through the static mixing tip thoroughly mixes the epoxy material, which can be directly
injected into a rubber impression.
EPOXY RESIN DIES

They cannot be used with water containing agar and alginate
impression materials because the water retards the polymerization
of the resin and thus are limited to use with rubber impression
materials .
Working time
- 15 min
Setting
time
- 1-12 hrs
(depending on product)
Shrinkage
Compressive strength - 9500-14200psi
Hardness
0.03%-0.3%
83Rhn
EPOXY RESIN DIES

ADVANTAGES: It
can be cured at room temperature without expensive or
complicated equipment.
It
is dimensionally stable.
Its
abrasion resistance is many times greater than gypsum
products.
High
strength.
EPOXY RESIN DIES

ADVANTAGES: Suitable
Detail
for fabrication of precise dies
reproduction is better than die stone
Hence
prostheses fabricated on resin die will fit more tightly
than those made of gypsum.

Good
results are achieved with silicone and polyether
EPOXY RESIN DIES

DISADVANTAGES: It
undergoes shrinkage during polymerization. But the amount of
shrinkage is approximately equal to the expansion with gypsum.

It
is more expensive than gypsum.
Not
compatible with impression materials such as polysulfide
and hydrocolloid
POLYURETHANE DIES
These
resins compared to epoxy resins were inexpensive and
easily manipulated.
Long
and narrow tooth preparations must be reproduced with
high transverse-strength working cast materials to avoid

fracturing
The
filled polyurethane resins could be indicated for these
conditions
SILICOPHOSPHATE CEMENT DIES

This is similar to the filling and cementing material.
Advantage :
Has
greater compressive strength than die stone.
Disadvantage:
Shrinkage
on setting.
Loss of water on standing.
AMALGAM DIES
Amalgam may be packed into rigid impression materials such as
compound.
Advantage:
-Produces a hard die
-Reproduces fine details and sharp margins.
Disadvantages:
-Can only be packed into a rigid impression .
-Long time to reach a maximum hardness.
METAL SPRAYED DIES

A
bismuth-tin alloy, which melts at 138oc, can be sprayed
directly on to an impression to form a metal shell, which can

then be filled with dental stone.
Advantage
-A metal coated die can be obtained rapidly from elastomeric
impression materials.
Disadvantage
-The alloy is rather soft, care is needed to prevent abrasion of
the die.
CERAMIC DIE MATERIALS:

Two ceramic die materials are available
A
material for the production of dies on which porcelain
restorations are to be fabricated, without the use of a platinum

foil matrix. To form the dies heating to over 10000c is necessary.
A
ceramic material, supplied as a powder and liquid, and mixed
to a putty like consistency. After 1 hour the material is removed

from the impression and fired at 6000c for 8 minutes to produce a
hard strong die.
FLEXIBLE DIE MATERIAL :

Similar
Used
to silicone or polyether impression material.
to make provisional restorations or indirect composite resin
inlays .
eg; polyvinyl medium viscosity impression material
Advantages:
-More rapid setting
-ease of removal of provisional or inlay
Disadvantages:
-expensive
Philip Duke et. al in 2000 conducted a study of the physical

properties of type IV gypsum, resin containing and epoxy die
materials. The results were all gypsum products expanded where
as the epoxy resin material contracted during setting. The epoxy
resin exhibited much better detail reproduction, abrasion
resistance, transverse strength than gypsum materials. In general
the epoxy resin exhibited the best properties of the materials
studied
Philip Duke et al ;Physical properties of type IV gypsum, resin containing and epoxy die materials
JPD April 2000 vol 83, no. 4 p-466-73
Jacinthe M et al in 2000 conducted a study on the dimensional

accuracy of an epoxy resin die material using two setting
methods and concluded that retarding the setting reaction of an
epoxy resin die material improved its accuracy. Epoxy resin die
materials had a net shrinkage but the gypsum based materials
had a net expansion .
Jacinthe M et al in 2000 dimensional accuracy of an epoxy resin die material using two setting methods. JPD
March 2000 vol 83 no3 p 301-305
DIE FABRICATION
Available methods for die fabrication:
A varied number of die systems or methods of fabrication have been
proposed, which may be broadly classified as follows:
A)
Working cast with a separate die (solved cast with individual die)
B)
Working cast with removable dies.
C)
Alternate / other die systems
WORKING CAST WITH SEPARATE DIE:

Technique:
2
casts are required in this technique of die fabrication:
Working cast for full mouth.

Sectional cast for die of tooth.
These
can be obtained by separate impressions or by pouring the
same elastomeric impression material twice.

If
a double pair is utilized, the first cast is used for fabrication of
die, because it is the most accurate.
Pouring an impression. Stone added

in the preparation area only.
Pours 1 and 2 (individual dies)

and 3 (definitivecast).
Sectioning the
individual dies
Sufficient bulk for the die

handles
The trimmed dies and definitive

cast before articulation.

Advantages:
Primary
It
advantage of this technique is its simplicity
keeps the relationship between the abutments fixed and
removable.
The
working cast requires only limited trimming and no additional
armamentarium is required for its fabrication.

Since
the gingival tissues around the prepared teeth are left intact,
they can be used as a guide when contouring the restorations.

It
also precludes errors caused by the removable die systems due to
incomplete seating of the die.

DISADVANTAGES:
It may be difficult to transfer complex or fragile wax patterns from

cast to die.
Seating
the pattern on the master cast may be problematic because
the second pour of many impression materials is slightly larger than

the first, therefore it may be necessary to relieve the stone slightly to
seat the pattern before occlusal evaluation.
This
technique can be used only with elastomeric impression
materials
WORKING CAST WITH A REMOVABLE DIE

In
a removable die system, the die is an integral part of the master
cast and can be lifted from the cast to facilitate access.

Precise
relocation of the die in the master cast is critical to the
success of this system is usually accomplished with brass pins or

dowels.

Technique
Several
methods can be employed to allow the repositioning of a die
in its working cast.

Prepour
technique: When the dowels are oriented in the impression
before it is poured.
Post
pour techniques: when they are attached to the underside of a
cast that has been poured.

Pre-pour technique
Advantage:
Gives more consistent accurate placement of dowel.

Disadvantages:
ItPositioning
makes pouring
more
difficult
(bubbles
maypins
occur).
dowel pins
before
cast pouring
with bobby
and sticky wax or with prefabricated wire tube aid
Sticky wax may break loose during vibration of impression.

Dowel
may settle into the stone.
Dowel pins must be carefully positioned
so that the first pour of stone
completely covers the knurled head; otherwise, the parts do not separate
cleanly.
However, the stone should not extend onto the shaft and reduce stability.

Post
pour technique
The
dowel will be cemented in holes drilled into flat underside of a
cast that has already been poured e.g. by Pindex system
The Pindex system consists of a special drill press and

brass dowels and plastic sleeves

Post
pour technique
The location of each dowel is

marked on the occlusal surface
Light indicates the location of the drill. The cast

is held firmly and the lever depressed; this
activates the drill, which penetrates into the cast
The pins are tried in and cemented in place
The assembly is coated with petrolatum

to ensure clean separation

Post
pour technique
The plastic sleeves are positioned.
The second pour of stone is made into the mold.

After some stone has been painted between the
pins, the first pour is placed into this mix
The assembly is placed in the special mold
Sawing the dies

Advantages:
Convenient to use because wax patterns or coping need not be
removed from the dies when transferred to working cast, this helps
to:
Decrease the chances of breakage during transfer of pattern.
This is also important for ceramic restorations as the unfired
material is quite fragile (up for labial porcelain margins).

Advantages
It
eliminates discrepancies between separate die and master cast that
may be caused by impression distortion or deformation between

pours by cast and die made from separate impressions that are not
identical.
A
removable die also eliminates discrepancies that can occur when
the die is coated with a relief agent and the working cast is not, or
when they are coated with different thickness

DISADVANTAGES
The
principal disadvantage of a removable die system is the risk
of an introducing an error in the pattern of the die does not reseat

accurately in the working cast.
Difficulty
may be encountered in sawing the die out of the cast
interproximal margins can be easily damaged, particularly if

clearance between proximal preparation margins and adjacent
tooth is minimal.
ALTERNATE / OTHER DIE SYSTEMS

Die lock trays
The
system involves the use of specially segmented trays.
With
a single-pour technique, the impression is formed in the usual
way.
The
Di-Lok tray is filled with stone and is inserted into the
impression while the stone is still wet.

After
the die stone has fully set, the locking and curved arms of the
tray are removed.

The
cast can then be removed by tapping the anterior pad of the tray
base.

DVA Model System
Trimmed impression on
alignment fixture.
Drilling holes for dowel pins as

marked.
Marking dowel pin locations on

clear plate
Inserting dowels in the baseplate.

An adhesive is not required.

DVA Model System
The impression is poured and stone

is placed around the dowel pins.
The alignment fixture is replaced

over poured impression
Finally the Set cast is removed from

the baseplate with gentle tapping.
The cast is trimmed and sectioned.
COMPATIBILITY OF DIE MATERIAL

WITH IMPRESSION MATERIALS
Dental stone
Electroplated Copper
Impression compound
Zinc oxide eugenol
Agar-agar
Alginate
Impression plaster when used with separator
Rubber base material
Rubber base material
Electroplated silver
Polysulphide
Polyether
Addition silicone
Epoxy Resin
Polyether, Addition silicone
Conclusion
A good
impression and an accurate die are the first step towards the
fabrication of an accurate restoration whether its inlay, onlay or

crown.
Proper
selection of the die material and its manipulation are
paramount to achieve accuracy in the die.

In
conclusion, a wise choice of material, combined with proper
handling and meticulous approach to the details of each step of

fabrication will bring us that much closer to perfection .
INLAY CASTING WAX
Inlay
wax is a specialized dental wax that can be applied to dies
to form direct or indirect patterns for the lost wax technique

used for casting metal or hot pressing of ceramics.
Generally
produced in deep blue, green or purple color.
COMPOSITION OF INLAY WAX

Paraffin-60%
Carnauba-25%
Beeswax-5%
Ceresin-10%
Natural resins(gum dammer)-less than 1%
Organic fillers- added to avoid excessive shrinkage,expansion due
to temp change
Microcrystalline wax- In minute amount.
Candelilla
Coloring agents

Paraffin wax(mineral wax) 60%
Generally
Melting
Likely
Does
the main ingredient of inlay waxes.
range 40-71o C.
to flake when trimmed.
not present smooth, glossy surface
Consequently
other waxes and natural resins are added.

Carnauba wax (plant wax) 25%
It
is quite hard, melting range 84-910C
Combined
with paraffin toDecrease flow at mouth temp

increase the hardness
It
contributes to glossiness of the wax surface.

Beeswax (insect wax) 5%
Melting
Brittle
Used
range 63-700C
at room temp, becomes plastic at body temp
to modify the properties of paraffin wax

Natural resin (gum dammar)
Less
than 1%
Added
It
to paraffin to improve its smoothness in molding
renders it more resistant to cracking and flaking
Increases
the toughness of the wax and enhances the smoothness and
lusture of the wax.

Organic Fillers
Normally
High
soft wax shrinks more than hard wax
shrinking wax may cause significant pattern distortion
when it solidifies.
For
this reason organic filler is added , they should be
completely miscible with components of inlay wax.

They
should not leave an undesirable residue after burnout.

Microcrystalline waxes(mineral)
Similar
to paraffin waxes.
It
has a higher melting range 60-910C
It
is tougher and more flexible than paraffin
It
has less volumetric shrinkage during solidification than paraffin.

Candelilla wax (plant wax)
Same
qualities as carnauba wax
Added
to paraffin to partially or entirely replace carnauba
wax.
Its
melting point is lower, and it is not as hard as carnauba
wax.
CLASSIFICATION OF INLAY WAXES

According to ADA SPECIFICATION 4
TYPE
1 -medium wax used for direct wax pattern
TYPE
2 - soft wax used for indirect wax pattern
DENTARUM (Germany)
Crown and Bridge Inlay Wax
In ropes
In bulk
Dark blue-hard, for crowns bridges and inlays.

Light blue-soft, for crowns bridges and inlays
Lilac-stress free, for copings and cervical margins
Red- adhesive, connecting and adhesive wax
Wax Preforms are available (ceratom wax preforms, Dentaurum)
It simplifies wax up and shorten finishing procedure.
DESIRABLE PROPERTIES OF INLAY CASTING WAX
1.) When softened the wax should be uniform.

2) The color should be such that it contrasts with the die material or
prepared tooth.
3) There should be no flakiness or similar surface roughening when the
wax is bent and molded after softening
DESIRABLE PROPERTIES OF INLAY CASTING WAX
4) During carving wax should not pull away with carving instrument or
should not chip as it is carved.
5) Wax should burn out , forming carbon which is later eliminated by
oxidation to volatile gases.
6) The wax pattern should be completely rigid and dimensionally stable
at all times until it is eliminated .
PROPERTIES OF INLAY CASTING WAXES

FLOW
Type of wax T=300C T=370C T=400C T=400C T=450 T=450C
(max) (max)
(min) (max) (min)
(max)
I
---
1.0
---
20
70
90
II
1.0
---
50
---
70
90
The
maximum flow permitted for Type I waxes at 37oC (98oF) is 1%.
Type
I and Type II waxes must have a minimal flow of 70% and a
maximum flow of 90% at 45oC (113oF).
PROPERTIES OF INLAY CASTING WAXES

THERMAL PROPERTIES
Thermal
conductivity of waxes is low and time is required to
both heat them uniformly and to cool them to body or room

temperature.
Inlay
wax thermally expand and contract more per degree of
temp change than any other dental material.

This
is one of the inherent disadvantages of waxes when they
are used in the direct technique.

A
maximum of 0.6% linear change in dimension when heated
from 25-37oC (77-99oF) is permitted for Type I wax.
MANIPULATION OF INLAY WAX

Armamentarium for manipulation of inlay wax
Top to bottom: PKT Nos. 1 to 5.
Electric waxing instruments.
MANIPULATION OF INLAY WAX

Armamentarium for manipulation of inlay wax
B
A
A. Top to bottom, No. 2 Ward and Nos. 1/2
and 3 Hollenback.
.
DPT6 Darby Perry trimmer (wax burnisher).
B. Left to right, closer view of these three

instruments.
Always heat the shank of the

instrument so that wax flows off its tip.
Wax pattern fabrication
Direct
wax pattern technique
Indirect

Direct
-with matrix band adaptation [closed technique]

introduced by Volland
-without matrix band adaptation [open technique]

introduced by Sturrock
-with copper band adaptation.
Indication
In easy accessible areas.
When cavity is small with minimal proximal extension.
When cavity walls are flat and line angles are definite.
Direct wax pattern technique

Advantages
The
pattern is carved on tooth and not on model.
Little
laboratory work compared to indirect technique.
Time
saving.

Disadvantages
Great
skill and patience is required to carve pattern in mouth
When
it is carved in indirect vision it is difficult and fatigue
Discrepancies
of the pattern at the gingival margin are difficult to
detect until the pattern has been carved and withdrawn

If
the casting fails, the patient has to be recalled

With Matrix Band Adaptation [Closed Technique]
Isolate the tooth using cotton rolls.
Apply matrix band and retainer.
Coat
the internal surface of band using separating media like vaseline.
Soften
the inlay wax by heating and moving it over a alcohol flame.
Compress
the softened inlay wax into the prepared tooth for few
minutes with finger pressure. This technique is called compression

technique.

Remove
excess of wax and do the carving. With a hot egg burnisher,
contour the occlusal portion of the wax pattern.

Now
remove the matrix band and retainer carefully without disturbing
the wax pattern.

Ask
the patient to bite in centric occlusion for a few seconds after
placing a thin layer of cotton soaked in warm water.

Examine
Do
the occlusal surface for high points and remove them.
the occlusal carving.

Pass
a floss through the contact area while holding the pattern in
place.
Smoothen
the proximal surface of the pattern with fine soft silk.
Evaluate
and correct all the margins of the pattern.
Burnish
and remove any excess wax over the axial margins with a
warm hollenback waxing instrument.

Finally,
examine the pattern. There should be a slight excess of wax
over the gingival margin.

Once
the satisfactory wax pattern is formed, attach the sprue former
and reservoir to the thickest point of the wax pattern

Remove
the wax pattern from the preparation and examine it for
marginal integrity.

Without use of Matrix Band Adaptation [OPEN TECHNIQUE]
Here
the technique is same except that matrix band is not used during
fabrication of wax pattern.
In this, after the carving of occlusal portion is done, use dental floss
to remove extra wax from the proximal portion and to produce proper
contact and contour..
INDIRECT WAX PATERN

INDICATIONS
Large
preparations like onlays, full coverage crowns and MOD
restoration.
Insufficient
When
access and visibility.
minute details like skirts and collars are present
INDIRECT WAX PATERN

ADVANTAGES
Easily
Less
made in inaccessible areas
chair side time
Direct
vision is used in pattern fabrication
Made
on articulated models better occlusal restoration
Polishing
If
is done outside the oral cavity
casting failure occurs, patient recall not necessary
INDIRECT WAX PATERN

DISADVANTAGES
Impression
Dentist
More
may be distorted.
depends on technician.
laboratory work.
Errors
in cast can result in inadequate casting.
Indirect wax pattern technique
The die is lubricated
The occlusal surfaces are developed

with a wax addition technique.
Proximal surfaces are developed,

with correctly located contact
areas
margins are reflowed, and the wax pattern is

finished
DISTORTION OF WAX PATTERN

Wax
distortion is probably the most serious problem during forming
and removal of the pattern from the mouth or the die.

Distortion
results from
-thermal changes
-relaxation of stresses (on cooling)
-occluded air
-molding
-carving
-removal and the time and temperature of storage
DISTORTION OF WAX PATTERN

Waxes
tend to return to their original shape after manipulation, this
property is known as wax memory.

The
casting fits best when the pattern is invested immediately after
its removal from the die.
Inlay wax softened over bunsen burner and left in room temp water for
several hours. It tends to return to its orignal shape, the inner mol were
under compression while outer ones under tension.
PREVENTION Of DISTORTION OF WAX

PATTERN
One
can minimize the incorporation of residual stress by softening
a wax uniformly by heating at 500C for at least 15 min before use ,

also by using warmed carving instruments and a warmed die, by
adding wax to the die in small amounts.
Greater
Inlay
distortion results at higher storage temperature.
wax pattern if allowed to stand longer than 30 minutes,
should be kept in a refrigerator , the distortion will be less as

compared to room temperature.

PATTERN
During
spruing distortion can be reduced by use of solid wax sprue or
hollow metal sprue filled with sticky wax. If the pattern was stored
margins should be re-adapted.
Sprue
position- Ideal area for the sprue former is the point of greatest
bulk in the pattern to avoid distorting thin areas and permit complete
flow of the alloy into the mold cavity.
It
should be attached with the pattern on the master die, provided the
pattern can be removed directly in line with its path of withdrawl

from the die.

PATTERN
Sprue
diameter- same size as the thickest area of the wax pattern ,
if the pattern is small, the sprue former must also be small.

Length
should be adjusted ,
Gypsum bonded investment 6 mm of the open end of ring

Phosphate bonded investment 3 - 4mm
Dental Investment
Material
INTRODUCTION
When a restoration or appliance is being made by a lost wax
process, the wax pattern is embedded in an investment material.
The wax is then removed from this mold, and the mold space thus
formed will be filled by the molten casting alloy from which the
restoration is to be made
DEFINITION
An investment can be described as a ceramic material which is
suitable for forming a mold into which a metal or alloy is
appropriately cast.
The procedure for forming the mold is described as investing.
Robert G Craig
As these materials can withstand high temperatures, they are also
known as refractory materials.
IDEAL REQUIREMENTS
Easily manipulated
Sufficient strength at room temperature
Stable at higher temperatures
Sufficient expansion
IDEAL REQUIREMENTS
Should
be porous enough to permit the air or other gases in the mold
cavity to escape easily during the casting procedure.

Should
have a smooth surface and fine detail and margins on the
casting should be preserved.

Investment
should break away readily from the surface of the metal
and should not have reacted chemically with it.

Should
be inexpensive.
CLASSIFICATION
A. BASED ON PROCESSING TEMPERATURE
High Temperature
I.
Phosphate Bonded Investment
II.
Silica Bonded Investment
Low Temperature
III.
B.
Gypsum Bonded Investment

BASED ON REFRACTORY MATERIAL
Quartz Investment
Cristoballite Investment
CLASSIFICATION
C. BASED ON TYPE OF BINDER USED
Gypsum bonded investments :
According to ADA Specification 2
Uses
Shrinkage compensation
Type I
Inlay, Crown
Thermal expansion
Type II
Inlay, Crown
Hygroscopic expansion
Type III R.P.D. Frame work Thermal expansion
Phosphate bonded investments
Silicate bonded investments
GENERAL COMPOSITION
Refractory Material
Material that withstands high temperature without decomposing or

disintegrating.
Resists heat and force of casting
Expands and compensates for casting shrinkage
Binder
The refractory material alone does not form a coherent solid mass, so
some kind of binder is needed. Commonly used binders are ;
- Calcium sulfate hemihydrate
Others are Sodium silicate, Ethyl silicate, Ammonium sulfate, Sodium
phosphate.
Other Chemical Modifiers
Usually a mixture of refractory materials and a binder alone is not

enough to produce all desirable properties required of investment.
Other chemicals such as sodium chloride, boric acid, potassium

sulfate, graphite, copper powder or magnesium oxide are often
added in small quantities to modify various physical properties.
GYPSUM BONDED INVESTMENT

ADA SPECIFICATION NO.2
TYPE-1
Inlays or crowns Thermal expansion
TYPE 2
Inlays or crowns Hygroscopic expansion
TYPE 3
Fixed partial dentures with gold alloys
COMPOSITION - GYPSUM BONDED INVESTMENT

1.
Binder
-Hemihydrate
Gives strength
Holds ingredients together
Provides rigidity

2.
Refractory
Silica
Quartz
Tridymite
Cristobalite
Fused Quartz
Silica (SiO2) is added to provide a refractory during the heating of
investment and to regulate thermal expansion.

If proper form of silica is employed in investment, the contraction
during heating in an investment can be eliminated and changed to an

expansion.

Quartz and cristobalite are of particular dental interest.
When quartz, tridymite or cristobalite is heated, change in crystalline form

occurs at transition temperature characteristic of particular form of silica.
Low form
(Alpha quartz)
High form
575C
( Beta quartz)
Cristoballite 200C to 270C

Tridymite 2 inversions at 117C & 163C.
Density decreases as alpha form converts to beta form, with resulting
increase in linear expansion.

3.
Modifiers
Reducing Agent
Coloring Agent
Carbon
Provides a non oxidizing atmosphere
Powdered copper
Modifying chemicals Boric acid, NaCl

Regulates Setting expansion & Setting time
Prevents most of the shrinkage when
gypsum heated above 300C
SETTING REACTION - GYPSUM BONDED INVESTMENT

Same as Dental stone.
CaSO4 H2O + H2O CaSO42H2O + 3900 Cal / gmol.
(Ca. Sulfate hemihydrate) (Ca. Sulfate dihydrate)
Sets to form a solid mass which binds the silica particles

together.
Reaction is exothermic.
Microstructure of set material shows rod like particles of

gypsum intermeshed with large irregular particles of silica
refractory.
PROPERTIES- - GYPSUM BONDED INVESTMENT

ADA Specification No. 2
Setting Time
9-18 minutes.
This can be altered by addition of K2SO4, NaCl (Increase setting time),

Borax and potassium citrate (decrease setting time).

Expansion
Expansion aids in enlarging mold.
This property of
investment is needed for compensation of casting shrinkage

of alloy.
Expansions are of 3 types :
Normal setting expansion.
Hygroscopic setting expansion
Thermal expansion

Normal Setting Expansion
Silica & calcinated gypsum results in setting expansion

greater than that of gypsum used alone.
Silica particles interferes with the intermeshing & interlocking of crystals as they form.
Thus, thrust of crystals is outward during growth, resulting in

increased expansion.
0.6% expansion.

Factors Affecting Normal Setting Expansion
Greater
the gypsum content of the investment, greater the
exothermic heat transmitted to the wax pattern and greater

the mould expansion.
Lower
the W/P ratio for the investment, greater the
exothermic heat and greater the setting expansion.

Factors Affecting Normal Setting Expansion
Thinner
the walls of the wax pattern, greater the setting
expasion of the investment.

Softer
the wax, greater the setting expansion. If a wax
softer than Type B inlay wax is used, the setting

expansion may cause a serious distortion of the pattern.

Hygroscopic Setting Expansion
This
occurs when the gypsum is allowed to set under or in
contact with water.

Hygroscopic
setting expansion of an investment may be more
than six times the normal setting expansion.

The
ADA specification no.2 for Type II investments requires a
minimal hygroscopic setting expansion of 1.2% and a maximal

expansion of 2.2%.

Hygroscopic Setting Expansion
Water
Immersion Technique :- the investment mould is placed
into water.
Water
Added Technique :- a measured volume of water is
placed on the upper surface of the investment material within

the casting ring.

Factors Affecting Hygroscopic Setting Expansion
Composition:- Increase in silica content increases the

hygroscopic setting expansion.
W/P ratio:- Higher the W/P ratio of the original investment

water mixture, less the hygroscopic setting expansion.
Spatulation:- Shorter the mixing time, less the hygroscopic

expansion
Shelf life of investment :- The older the investment, less is its

hygroscopic setting expansion

Confinement
:- Both the normal and hygroscopic setting expansions
are confined by opposing forces, such as the walls of the casting ring or
the walls of the wax pattern.
Temperature
of the water bath :- Higher the temperature of the water
bath used for immersion, greater the hygroscopic expansion

Amount
of added water :- An increase in the amount of water added,
increases the hygroscopic setting expansion upto a certain point, after

which further addition of water does not create any expansion

Particle
size of silica :- Finer particles of silica produce greater
hygroscopic expansion
Silica/binder
ratio :- If this ratio increases, greater will be the
hygroscopic expansion and lesser the strength.

Thermal Expansion
Thermal expansion of gypsum is directly related to amount of silica

present & to type of silica employed.
The thermal expansions of type II investments to be between 0.0 to

0.6% and of Type I investments which rely principally on thermal
expansion for compensation, to be between 1.0 to 2.0%.

Thermal Expansion
Thermal expansion is influenced by particle size of quartz, type of

gypsum binder & resultant W/P ratio to provide workable mix
Investments containing cristobalite expand earlier than those

containing quartz.
Expansion occurs at a lower temperature because of lower inversion

temperature of cristobalite compared to quartz.

Strength
Must be adequate to prevent fracture or chipping of mould

during heating and casting of gold alloy.
Contraction of investment is fairly constant until it cools below

5500C. Thus, when alloy is still quite hot and weak, investment
can resist alloy shrinkage by virtue of strength and constant
dimension.
Compressive strength 2-4 MPa.

Factors Affecting Strength
1.
Alpha hemihydrate ----- strength
2.
Modifiers -------
3.
Water
4.
Heating investment to 700oc may increase or decrease strength
strength
depending on composition.
5.
After investment has cooled to room temparature its strength

decreases.
PHOSPHATE BONDED INVESTMENT
PHOSPHATE BONDED INVESTMENT
Most common type of investment for casting high melting alloys is

phosphate bonded investment.
Common Brands
Silikan, Auro bond, Calsite, Deguvest, Eurocent, Nirobond, etc.
COMPOSITION
Binder- 20%
Acidic part ammonium diacid phosphate
Basic part magnesium oxide
Refractory- 80%
Silica (cristobalite or quartz or mixture of two)
Provide high temperature thermal shock resistance
Provide thermal expansion at high temperature
Modifiers- Carbon
Acts as reducing agent
MODE OF SUPPLY
Powder + liquid
POWDER
Ammonium
diacid phosphate
Magnesium
oxide
Silica
Traces
of carbon
LIQUID
Colloidal
silica
SETTING REACTION
NH4H2PO4 + MgO NH4MgPO4 + H2O
OR
NH4H2PO4 + MgO +H2O NH4MgPO4.6 H2O
SETTING AND THERMAL EXPANSION
When phosphate bonded investments are mixed with water they

exhibit shrinkage between 2000C to 4000C.
This contraction is eliminated when colloidal silica replaces water.
SETTING AND THERMAL EXPANSION
Early thermal shrinkage of phosphate bonded investments is

because of decomposition of binder and is accompanied by
evolution of ammonia.
For gypsum, shrinkage is caused by transformation of calcium

sulfate from hexagonal to rhombic configuration.
Working And Setting Time
Working Time - 2 minutes
SettingTime - 1 hour
Warmer the mix, faster it sets.
Increased mixing time, faster is the set.
Increased L/P ratio, increased is working time.
PROPERTIES
Compressive strength ----- 2.5- 3 Mpa
Setting expansion
Hygroscopic setting expansion ------ 0.8%
Thermal expansion with water----- 0.8%
With special liquid ---1.2%
------ 0.4%
ADVANTAGE
1.
High green strength
2.
High fired strength less mold cracking and few fins on

casting
3.
Can withstand temperature up to 1000c for short period

of time
DISADVANTAGES
4.
Temperature of 1375c ----- mold breakdown and

roughen surface of casting
5.
Special liquid
casting
6.
Produces oxides difficult to remove from castings
---- less porous mold -----incomplete
SILICATE BONDED INVESTMENTS

These investment materials are being used since 1930 but are slowly
loosing there popularity due to complicated and time consuming
procedures involved.
COMPOSITION
Binder ---- silica gel
Refractory ------ silica
Additives---- magnesium oxide
Wetting agent
PROPERTIES
Compressive Strength 1.5 MPa
Setting Contraction
Thermal Expansion
0 - 0.4%
1.5 1.8%, this has only
thermal expansion.
Can Withstand High Temp 10900C to 11800C
Advantages
1.
High permeability, yields sharply defined castings
2.
Low setting expansion
3.
Smooth castings
4.
Low burnout strength easy removal of casting &

cleaning of oxides from castings
Disadvantages
5.
Limited shelf life of liquid
6.
Very expensive
7.
Gives off flammable components during processing
8.
Potential of cracking during burnout.
Investment
Primary use
Dental plaster or stone
Mould for acrylic dentures.
Gypsum-bonded materials
Mould for gold casting alloys.

Mould for base metal and gold
Phosphate-bonded materials
casting
alloys,
mould
for
cast
ceramics and glasses; mould for

soldering.
Silica-bonded materials
Mould for base metal casting alloys.
PROBLEM CAUSED BECAUSE OF INVESTMENTS

PROBLEM
CAUSE
SOLUTION
ROUGH SURFACE
BREAKDOWN OF
INVESTMENT
DONT OVERHEAT
MOULD OR ALLOY
AIR BUBBLES ON
WAX PATTERN
WETTING
AGENT/VACCUM
INVESTING TECHNIQUE
WEAK
INVESTMENT
AVOID USING EXCESS

WATER OR TOO MUCH
WETTING AGENT ON
WAX
FINS
CRACKING ON
INVESTMENT
AVOID HEATING
INVESTMENT RAPIDLY
SULPHUR
BREAKDOWN OF
INVESTMENT
DONT OVERHEAT
ROUNED
MARGINS
BACK PRESSURE OF AIR

DUE TO LOW POROSITY
OF MOULD
PATTERN 6-8 MM FROM

END OF CASTING RING
RECENT ADVANCEMENTS
More recently new investment materials have been marketed for

casting commercially pure titanium.
These investments are based on alumina, spinels, zirconia and

magnesia.
The objective in developing these investments has been to

minimise the interactions between molten titanium and the
investment moulds on casting.
In the magnesia-based investment the expansion is

controlled using zirconium.
As this reaction occurs, investment expands.
INVESTING
Two
main methods of investing the wax pattern
are:
1.
Hand investing.
2.
Vacuum investing.
INVESTING
With the crucible former in place, the

ring is attached tothe mixing bowl.
The mix is hand-spatulated
The vacuum hose is attached
INVESTING
The bowl is inverted, and the

ring is filled under vibration
The vacuum hose is removed

before the mixer is shut off
The filled ring and crucible former are removed

from the bowl.
When the investment has set, the skin at the

top of the ring is trimmed off.
The rubber crucible former is removed,

and any loose particles of investment are
blown off.
The ring is then placed in the furnace for

the recommended burnout schedule.
References:
Philips science of dental materials - Anusavice
Notes on dental materials - E C Combe
Restorative dental materials - Robert G Craig
Fundamentals of fixed Prosthodontics - Shillingberg.
Contemporary fixed Prosthodontics - Stephen F.Rosenstiel
Philip Duke et al ;Physical properties of type IV gypsum, resin

containing and epoxy die materials JPD April 2000 vol 83, no. 4
p-466-73.

Die Materials, Investment and Inlay Wax

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Die Materials, Investment and Inlay Wax

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Die, Inlay Wax And Investment

Ideal requisites of inlay wax

Types of investment materials

Indications of each investment materials

restorations are usually not feasible and advisable in teeth

where more than half the tooth structure is lost.

such scenarios the indirect restorations come into play

provide the requisite resistance and retention form as well

support the remaining tooth structure.

indirect restorations are also indicated as treatment options

over direct restorations in conditions where the anatomical

casting method for fabrication the indirect

restorations basically consists of:

Accurate reproduction of the prepared tooth, its

Forming a wax pattern,

Surrounding it with a suitable investment material,

Heating the investment mold to remove the wax

fabrication of indirect restorations, accurate

reproduction of the tooth, its relation with adjacent teeth

is where the role of a die comes into play.

is the positive reproduction of the form of the prepared

tooth in any suitable substance.

die is a positive reproduction of the prepared tooth

and consists of a suitable hard substance of sufficient

reproduction of a prepared tooth made from a gypsum

product, epoxy resin, a metal or a refractory material.

die is a model of the individual prepared tooth on

which the margins of the wax patterns are finished.

IDEAL REQUIREMENTS OF A DIE MATERIAL

should accurately reproduce all the details in the

should be dimensionally stable.

die should have a smooth surface and the ability to

They should be compatible with impression materials

IDEAL REQUIREMENTS OF A DIE MATERIAL

die should have toughness to resist breakage during

fabrication or burnishing of fine edges.

of the die should be in contrast to the colour of

wax. This helps to facilitate the manipulative procedures

should be reasonably easy to use without excessive

IDEAL REQUIREMENTS OF A DIE MATERIAL

should be relatively inexpensive.

be compatible with separating agent used.

should be easily wettable by the wax.

TYPES OF DIE MATERIALS

wide variety of materials have been used for the

fabrication of the dies. They may be broadly classified as

Dental stone Type 4, high strength.

TYPES OF DIE MATERIALS

filled resins or inorganic filled resins.

OR REFRACTORY DIE MATERIALS:

preparation of wax patterns.

TYPES OF DIE MATERIALS

Selection of the type of die material usually depends on:

impression material used.

for which the cast or die is used.

that will be manipulated on the cast or die.

to ADA specification No. 25 the gypsum

products are classified as follows :

Type I Impression plaster

Type II Model plaster

Type III Dental stone

Type IV Dental stone, high strength

Type V Dental stone, high strength and high