RULESAND

RULES ANDGUIDELINES
GUIDELINES
FORLABORATORY
FOR LABORATORY
PROCEDURES
PROCEDURES
IN
IN
FABRICATION
FABRICATION OFOF

COMPLETE
COMPLETE
DENTURE
DENTURE
PRESENTEDBY
PRESENTED BYDR.SUDESNA,PG
DR.SUDESNA,PGSTUDENT
STUDENT
 Introduction
• Lab. procedures in fabricating complete
dentures include all the procedures done in
the lab by the dental technician in other to
produce the compete denture.
• In the fabrication of complete dentures the
contribution of the dental technician can
not be over emphasized.
• The dental technician contribution is
directed towards the careful translation of
the prescribed denture design into the
denture itself and also the accurate
construction of the denture.
Lab. Stages in fabricating
CD
• These stages include:
• Diagnostic cast
• Primary cast
• Special tray
• Master cast or working cast
• Bite block occlusal rims
• Arrangement of the teeth
• DentureProcessing
• Finishing and Polishing
Purpose of making a
diagnostic cast.
• To measure the depth and extent of the
undercuts.
• To determine the path of insertion of the
denture.
• To identify and plan the treatment for
interferences like tori.
• To determine the amount of
preprosthetic surgery required.
• To evaluate the size and contour of the
arch
• To determine the need for additional
retentive features like over denture
Types of impression

Primary

secondary
 Primary impression

• Negative replica of the • Made for the purpose

oral tissues of diagnosis or
treatment planning or
construction of tray
--GPT
 TRAY Specification
• Stiff to prevent distortion.

• Workable thickness must be 4mm.

• Altered in areas hindering the ridge.

• Borders - 2mm short of vestibule.

Tray selection
 Impression
materials
Impression
Irreversible hydrocolloid
compound

Perforated Non-
tray perforated
tray.
 Conditioning the
impression
• Disinfection
- immersing in disinfectants for
10 mins
2% glutaraldehyde
iodophor
• trimming excess with BP blade
 Pouring the diagnostic cast
• The cast should be poured within
15mins after impression making.
• A base former can be used to make a
proper base.
• Usually a diagnostic cast is poured
using dental plaster because it is
economical and reproduction of finer
details is not of important requisite.
• the impression is placed and stabilized
over a piece of cotton so that the ridge
appears parallel on the table.
• impressions are usually poured in three
pours. The 1st pour should be of more
liquid consistency. The plaster mix should
be allowed to flow all over from the distal
end. It should be placed on the vibrator to
avoid the occurrence of air bubbles.

• The 2nd pour should be a little thicker in

consistency. The 3rd pour or base is done
usin a base former. The base should have a
minimum thickness of 10mm at the
thinnest portion.
 Primary cast
• Pour the plaster in •
the impression in • Pouring should be
3 steps. done from distal
end.
• Done within • Trimming
15min after
impression making.

• Base should have

10mm thickness.
PRIMARY CAST
Requirement of cast

• Free of voids.
• Record the details accurately .
• Extend 3 to 4mm beyond
retromolar pad .
• Moisture free.
PRIMARY SUPPORT
MAXILLARY MANDIBULAR
• Flat areas of palate • Buccal shelf,
• ( right angles to occlusal
forces and they do not
resorb easily).
Posterior ridges slopes

.
SECONDARY SUPPORT
MAXILALRY ARCH MANDIBULAR AR ARCH
• Rugae
• Maxillary tuberosity • Alveolar ridge slopes
.
 RELIEF AREAS
Maxillary Mandibular

• Incisive Papilla • Crest of alveolar ridge

• Mid palatine raphe • Mental foramen
• Fovea Palatina • Genial tubercles
Special tray

• A custom made device

prepared for the particular
patient which is used to
carry confine and control
an impression material while
making an impression--GPT
 Why is it needed?
• Overview Of Border Molding .

• To Support Low fusing Compound.

• To Make Out Final Impression .

• To Provide optimal Thickness Of The

Impression Material.
 Requirements
• Well adapted to the primary cast .
• 2mm thickness

• 2mm relief near the sulcus.

• Free of voids & projections in the
tissue surface.
Conditioning the
primary cast
• Soak in slurry water

 Draw the outline on the cast.

 Block out the undercuts using

wax.

 Place the wax spacer on the

cast.
Why is a spacer needed?
• record tissues in a state of anatomical
rest.
• Provide space for impression material
• Relief the non stress bearing areas .

Spacer:

• 2mm thick.
• modelling wax.
 SPACER &TISSUE STOPPERS
DESIGNS ACCORDING TO

BOUCHER RUDD &

MORROW
 SPACER & TISSUE STOPPER
DESIGNS ACCORDING TO

SHARRY BERNARD LEVIN

 SPACER &TISSUE STOPPERS
DESIGN ACCORDING TO
Dr Sanath Shetty et al JIPS 2007
• Fabrication of the special tray depends on
the type of material used. Most commonly
used materials include:
• Shellac
• Cold cure acrylic
• Vacuum formed vinyl or polystyrene
• Vacuum formed thermoplastic resin
• Type II impression compound (tray
compound)
 Fabrication of special
tray from shellac
• The shellac material is thermoplastic.
This means it is soften on heating and
solidified on cooling. They are supplied
in lower and upper shellac sheets. The
lower is like horse-shoe shaped pattern
while the upper is half rounded flat
sheet. 
• Outline with an indelible pencil the tray
coverage area on the preliminary casts.
• Sock the primary cast in water for few minutes
• Adapt the spacer on the model.
• The thickness should depend on the
impression material to be used .i.e.
• Zinc oxide eugenol impression material
– 0.5mm
• Rubber based impression material - 0.5
-1.5mm
• Depending on viscosity - light = 0.5mm
• -regular/ medium = 1mm
• - heavy= 1.5mm
• Impression plaster--- 1.5mm
•
• Gently flame the shellac tray material over
flame until it softens, care must be taken not to
melt it or burn.
• Adapt the soften shellac on the primary cast
with the spacer in between.
• Trim off the excess i.e over extension with
scissors or trimming knife to the pencil outline.
• Construct handles from the scrap and attaches
it at the midline.
• Perforate the trays so as to allow retension of
the impression material and flow of excess
impression material.
• Check for correct extension, fit and any rough
edges.
• Smoothen the edges of the trays all round.
Fabrication of special tray
using cold cure acrylic
material
• It is also known as the auto-
polymerising resin. The material sets by
chemical reaction and hence it is
irreversible.

• It is similar to the denture base resin

used for the final fabrication of the
denture.
 Procedure
• The relief areas and borders of the special tray
are marked by an indelible pencil on the
primary cast. A wax spacer is adapted on the
relief areas.

• Separating medium is coated on the entire cast

and over the spacer.

• There are two major techniques commonly

used in the fabrication of an acrylic special
tray.
Fabrication of custom tray
(cold cure resin)

Sprinkle on
technique

Dough technique
 Sprinkle on technique

• The powder and liquid are loaded in

separate dispensers.
• A small quantity of powder is sprinkled on
a particular area
• Sprinkling drops of the liquid polymerizes
the powder.
• This is continued till the entire ridge and
the associated landmarks are covered.
• The advantage of this technique include its
ease of use and minimal wastage of
material.
• The disadvantages are: even thickness
cannot be obtained, too many porosities
 Dough technique

• L/P ratio – 1 : 3
• After mixing monomer & polymer undergoes
six stages
- wet sandy
- early stringy
- late stringy
- dough
- rubbery
- stiff
 Manipulate in dough stage.
 Knead to achieve a homogenous mix.
• Adapt the rolled sheet from centre to periphery.
• Remove excess with BP blade.
• After cutting hold in position to prevent
shrinkage & warpage during polymerisation.
• Trimming .
 Handle
• Place anteriorly.
• 3mm thick
• 8mm long

• 8mm high.
• Should be parallel to the long axis
of the teeth.

Soak the tray in water to prevent warpage

 Other materials used for
making special trays
• Thermoplastic resins:
• These are also very good special tray
materials. They are adapted using a vacuum
former.

• Vacuum-formed vinyl polysterene:

• This is the fastest method for making
special trays. Its only disadvantage is that it
is very expensive
Polystyrene Trays
Light-Cure Special Trays
 Secondary impression
• Negative likeness made for the purpose of
fabricating a prosthesis.
• It should have the finer details of denture
bearing area at rest .

Steps:
 border molding / peripheral tracing
 make wash out impression
 Border molding/ peripheral
tracing
The shaping of an impression material by
manipulation or action of tissues adjacent to
the borders of the impression --GPT

Techniques involved :

simultaneous border moulding

incremental border moulding
 Tray preparation before imp.
making
• Wax spacer should be removed.
• Remove 0.5 – 1mm of tracing material
but not in post. palatal seal.
• Drill holes in tray to prevent tissue
displacement during imp.making.
 Beading and boxing

• Beading is done to preserve the width and

height of the sulcus in a cast. Beading waxes
are generally blue in colour.

• Boxing is done to obtain a uniform, smooth,

well-shaped base for the cast. Boxing waxes
are white in colour.

• Other beading and boxing waxes include

modelling wax,
 Procedure
• The impression should be stabilized using soft
wax or modelling clay to make the impression
parallel to the floor.
• For a mand. impression, the tongue space
should be covered with a sheet of wax.
• The beading wax is adapted 3-4mm below the
height of contour of the impression flanges.
The beading should at least 4mm wide and the
width should be even all around the
impression.
• The beading wax should be sealed on both
sides (above and below) to the impression .
• The beaded impression is positioned on the
table. A strip of boxing wax about 15mm wide
is heated and adapted around the beaded
impression to form a base for the cast.

• Water should be poured into the boxed

impression to check for leakages.

• After beading and boxing the master cast is

poured with dental stone with w/p ratio 0.28 to
0.30

• The three-pour technique is employed.

 Materials used
beading --- utility wax

boxing --- plaster with pumice ,

paddle boxing and caulking
compound .
 Master cast

Replica of the tooth structures ,

residual ridge areas and
other parts of the dental arch
or facial structures used to
fabricate a dental restoration
or prosthesis--GPT
INDEXING THE MASTER
CAST
• To accurately remount the cast in an articulator
in a proper position
• Requirements---Should not weaken the
cast,,easy to fabricate,no undercut,permit easy
removal and placement of the cast.
• Types
• Groove indexing
• Notch indexing
• Split remounting plates for indexing
Bite block
• Bite block is defined as occluding surfaces
built on temporary or permanent denture bases
for the purpose of making maxillomandibular
relation records and arranging teeth--GPT
• Bite blocks are used to record jaw relations.
They are used to establish such a correct
relationship of the mandible and maxilla after
which teeth are arranged in the block for trying
in at a later day.
•  
• They consist of 2 parts: (1) The denture base
(2) The Rim
•  
• The base plate can be of two types:
• (1) Temporary base plate
• (2) Permanent base plate.
• Temporary base plates that could be
used are: (i) wax (ii) shellac (iii) cold
cure acrylic

• These temporary base plates are

discarded at the flasking stage of
denture fabrication.
•  
• Permanent base plates: This forms the
denture base and part of the final
product. The materials that can be used
are heat cure acrylic resin, light cure
acrylic resin, microwavable acrylic
resins and metals.
 
 Denture base
• Base of denture .
• Support wax occlusal rims.
Requirements :
 Well adapted to the final cast .
 Dimensionally stable.
 Retentive .
 1mm thick on the crest and facial slope of the
ridge .
 2mm thick in the palatal and lingual flange.
 Smooth and rounded borders.
Stabilising materials

• ZnOE. By Fletcher
• Elastomeric impression
materials .By Freese
• Cold cure resins. By Boos
 Occlusal rims
Occluding surfaces built on temporary
or permanent denture bases for the
purpose of making maxillo-
mandibular relation records and
arranging teeth.

o Primarily serves as lost soft tissue

o Done mainly to arrange teeth
Occlusal rim techniques

 Rolled wax technique

 Pre-formed occlusal rim
 Metal occlusal rim former
 Maxillary occlusal rim
• 22mm high from the depth of the sulcus.
• Ant region should be 8mm away from
incisive papilla .
• 4 – 6 mm wide in ant region.
• Occlusal table should be 18mm high from
the depth of sulcus posteriorly.
• Occlusal table should be 8 – 10 mm wide
posterior.
• Occlusal table should be 10 – 12 mm above
the crest of alveolar ridge anteriorly.
 Mandibular occlusal rim
• 6 -8mm high from the crest of the ridge
anteriorly
• 18mm high from depth of the sulcus in the
canine eminence region
• 3 – 6mm high from the crest of the ridge
posteriorly
• The occlusal plate should extend to 2/3rd ht of
the retromolar pad posteriorly
• Width
anteriorly 4 – 6mm
posteriorly 8 – 10mm
Clinical guidelines for determining the
shape of Bite blocks

• Maxillary anterior edge should be 0-2 mm below the upper lip

at rest.
• Mandibilar incisal edge should be at the level of the lower lip
and about 2mm behind the maxillary incisal edge.
• Canine eminence of the lower occlusal rim must be located at
the corners of the mouth.
• Posterior part of the lower occlusal plane should extend to two
third the height of the retromolar pad.
• The anterior occlusal plane should be parallel to inter pupillary
line
• The posterior plane should be parallel to alar tragal line.
 Facebow
A Caliper like Device Used To
Record The Positional Relations
Of The Maxillary Arch To The
Tempromandibular Joints And To
Orient Dental Casts On
Articulator In This Same
Relationship To The Opening
Axis Of The Temporomandibular
joint--GPT
Mount Maxillary Cast
Same Relationship to
Transverse Hinge Axis
Centric Relation Registration
Ant/Post & Mediolateral
Relationships
Mount Mandibular Cast on
Articulator
 Articulation
The procedure of attaching the
maxillary and mandibular casts to the
articulator in the recorded jaw
relations.
Mounting procedure:
 Zeroing the articulator.
 Mounting the maxillary cast.
 Mounting the mandibular cast.
 Teeth arrangement
Maxilla:
Mandible:
Overbite and overjet

vertical overlap.

• Horizontal overlap.
 Wax Up
The contouring of a pattern in wax
generally applied to
shaping in wax of the contours of a trial
denture--GPT
REQUIREMENTS
 Aesthetics.
 Functions of denture.
 Prior to try -in for better treatment
outcome .
 Retentive quality.
 Imitate the tissues around the natural
teeth.
 PROCEDURE
• A softened rolled baseplate wax is
kneaded and adapted over the cervical
area of the teeth.

 Should give convex contour to the

dental flange.

 Concave flange contour to molar

regions.

 Prominent bucco-gingival margins.

Festooning :
• By creating depressions interdentally.

Carving :
• Wax should be carved around the neck
of the tooth with wax spatula.
• Anteriors- 60degree.
• Posteriors – 45 degree.
• Thin down near neck of the teeth for
free gingiva.
• Stippling is produced interdentally
with a tooth brush or bristle brush in
the region of attached gingiva.

• Effective in regions of interproximal

areas.
 Polishing
• Polish by flaming and wiping with
cotton.
Polish with damp nylon stocking in
rough areas.
Normal thickness – 2mm -2.5mm.
 DENTURE
PROCESSING
 Denture processing

Involves Replacing The Base

Of Waxed Portions With Final
Denture Materials
 TECHNIQUES

• COMPRESSION MOULDING
TECHNIQUE

• INJECTION MOULDING TECHNIQUE

• LIGHT CURED TECHNIQUE

• FLUID RESIN TECHNIQUE

• MICROWAVE CURED TECHNIQUE

Steps in compression
moulding technique
• Preparation of the trial denture
• Disaticulation
• Flasking procedure
• Dewaxing
• Application of separating medium
• Mixing of powder and liquid
• Packing
• Curing
• Cooling
• Deflasking
 Cast Preparation
 Sealing:
The Denture Is Sealed To The
Cast At Its Borders With Molten Wax.

 Cast Separation.
 Why sealing is done ?
• It Helps To Maintain
Position Of The Denture.

• Mainly Prevents Plaster

From Getting Under The
Denture.
Remove Denture from
Articulator
Flask for Processing
 Flasking / Investing
• Process by which trial denture is
surrounded by stone / plaster in a
metal flask .
• It basically creates a mold for
acrylic denture.
 Flasking Techniques
• Two Pour
• Three Pour

Ideal Material For Investing - Stone

 Two Pour Technique
• First Pour
Cast Is Flasked In Lower Half.
• Second Pour
Rest Of The Flask Is Filled.

Disadvantages :
• Difficult To Deflask
• Risk Of Fracture
• Risk Of Distortion
 Three Pour Technique
• Soak the cast in slurry water.
• Checking the fit .
• Excess height is trimmed off.
• Lubricate using petroleum jelly .

Advantage:
• Reduces the possibility of distortion
and fracture.
• Deflasking is easier.
 First pour:
• Separating media is applied at base and sides.
• Stone filled in the lowest portion.
• Allowed to set for 20mins.

Second pour:
• Apply separating media over 1stst pour .
• Middle portion of flask is assembled and pour the 2ndnd

mix till the occlusal surfaces of teeth and allow to

set for 20mins.
• Excess stone is removed to expose cusp tips .
 Third pour:
• Separating Media Is Applied
Again.
• Stone Mix Is Poured Filling
The Remainder Of Flask.
• Allow To Set For 20mins.
Dewaxing
• Eliminates the wax and temporary
denture base for mould space.

• Place in boiling water for 5mins.

• Excess time in boiling water

causes wax liquify and soak in
stone.

• Opened flask is flushed with

boiling water to remove remaining
 Separating Media
Separating Media Is Applied To The
Dewaxed Mold Space Prior To Packing
The Acrylic Resin
Objectives:
 Prevent Water From Mold Entering Into Resin
Which May Affect The Rate Of
Polymerisation.
 Prevent Monomer Penetrating Into Mold
Material , causing Plaster To Adhere To The
Resin And Producing A Rough Surface.
 Types of separating medias
 Tin foil
 Cellulose lacquers
 Solution of alginated compounds
 Calcium oleate
 Soft soaps
 Sodium silicate
 Starches
Most commonly used separating medium
is sodium alginate solution which is also
called as ‘cold mould seal’.
Mixing of powder and
liquid
• The powder/liquid ratio used is
dependent upon the character of powder
including the particle size and shape.
•
• It is always quoted by the manufacturer
for a specific product and the instruction
should be carefully followed.

• The critical factor is the ability of the

liquid to wet all the powder completely
and this is usually achieved with a liquid
• Excess liquid is undesirable as this gives
a greater amount of polymerization
shrinkage.
•
• Measuring devices are usually provided
by the manufacturer.
•
• The mixing is done for a short time
typically 45seconds and then allowed to
stand in a clean container to prevent
evaporation of the volatile monomer for
a length of time determined by the
manufacturer.
• The monomer first melts the powder and produces a
coarse-textured material with a texture similar to that
of wet sand (sandy stage).

• As the monomer starts to dissolve the surface of the

polymer particles, the mixture becomes tacky (tacky
stage) and then as it become saturated with more and
more polymer in solution it looses it tackiness and
forms a dough (dough stage).

• At this dough stage, it is ready to be packed into the

mold.
• The material should not be left longer than the dough
stage before packing since it becomes too rubbery
(rubbery stage) and eventually quite stiff (plastic).

• The dough time is influenced a number of factors:

• (i) Powder –liquid ratio. If a high powder/liquid ratio

is used, it is reduced.

• (ii) Small powder particles and lower molecule

weight of the polymer also aid rapid dissolution and
give shorter dough time. The same effect is produced
by raising the temperature and conversely
 PACKING
• Apply separating media on to the
stone surface excluding the teeth.
• Mixed acrylic dough is formed
into a roll and adapt into mould
space.
• A plastic separating sheet is
placed over the dough and 2
halves are closed with pressure.
  The Flask Is Separated And
Excess Is Trimmed Off.

 In Final Closure Remove The

Separating Sheet.

 Flask Is Transferred To Clamp

And Resin Is Allowed To
Expand.

 Flasks Are Secured In Clamp

And Placed Aside For 30mins.
 WHY
?
• Permits equilization of pressure.

• Allows time for uniform dispersion of

monomer.

• Helps in better bonding of tooth with base

material.
 Curing
• Polymerisation.

• It Is Defined As Forming Of A Compound By

Joining Together Of Molecules Of Small Mol.Wt
Into A Compound Of Large Mol.Wt.
 Equipment
Spl Electrical Curing Chambers

Short Curing Cycle

 Flask Is Kept In Water At
Room Temp. Is Raised For 74
Degree And Maintain For 2hrs.
 Boil For 1hr.
 Long Curing Cycle
• Slow.
• Cure At Low Temperature For
Long Time For Thick Dentures.
• Less Prone To Porosity.
• Temp – 74 Degree.
• Time – 8hrs.
• No Need To Boil.
 Cooling
• Slow Cooling
Bench Cooling

• Fast Cooling
Bench Cooling For 30mins And
Placing It Under Running Tap
Water For 15mins.
 DEFLASKING
• Removal of denture from flask
using a wedge instrument.
 INJECTION MOULDING
TECHNIQUE
• Introduced by Pryor in 1942.
• Resin used---Thermoplastic resin
• Technique—A sprue hole and a vent hole are
formed in mold.The soft resin is contained in
the injector and forced to mold space.Kept
under pressure till it hardens.
• Advantages---Low shrinkage,low free
monomer content,good impact strength
• Disadvantages—High cost equipment,difficult
mould design,special flask is needed.
 FLUID RESIN TECHNIQUE
• The principal difference is that the pour type
denture resins have high molecular wt. smaller
powder particles,when mixed with
monomer,the mix is very fluid,so called fluid
resin.
• Agar hydrocolloid is used for the mold.
• fluid mix is quickly poured in the mold and
allowed to polymerize under pressure at 20psi.
Polymerization for 30-45mins.
• Advantages—Better tissue fit,no trial
closure,less chances of fracture of teeth
• Disadvantages—Air inclusion,High
polymerization shrinkage,low impact strength
 LIGHT CURE TECHNIQUE
• Resin consists of urathane dimethacrylate with
acryllic copolymer,sillica fillers and
camphoroquinone amine photo initiator.

• Supplied in pre mixed sheets

• Base material adapted to the cast

• Polymerised in light chamber with blue light of

400-500nm from high intensity quartz halogen
bulbs
• .
• Denture is rotated in the chamber to provide
• Advantages—Less porosity,less
polymerization shrinkage,free of
residual monomer.

• Disadvantages—Required high artistic

skill,technique sensitive,depth of
depends on light intensity and distance
of source and resin,time consuming.
 MICROWAVE CURED
TECHNIQUE
• Nishii in 1968 use microwave energy to
polymerize denture base resins using 400wt
oven in 3mins.
• The denture is invested and cured in unique
flask made up of non metallic polycarbonate or
fibre re-inforced plastic flasks.
• Technique---The heat required to break the
initiator benzoiyl peroxide molecule into free
radicals is created within the resin by the
collision of monomer molecules due to the
electromagnetic field created from the
microwave.
• Advantages—Reduced curing time,minimal
TRIMMIN
G

Excess should be trimmed off

to reproduce the accurate
details.
Lathes Used For Trimming
 Types:

Pumice:
 Siliceous Material Of Volcanic Origin.

 Used As Both Abrasive/Polishing

Agent Depending On Particular Size.
 Carbides:
• Silicon carbide , boron carbide - abrading
agents.
• The silicon carbide is sintered / pressed
with binder into grinding wheels/ disks.

Eg: most of the stone burs are made of

SiC.
Trimming:
 For trimming borders:
lathe mounted arbor band.
laboratory sized carbide burs.
 For deeper frenum notches:
fissure bur mounted on lathe.
 To remove stone in between. Teeth/ to
remove acrylic nodules from denture:
pointed chisel/ fissure bur
 To finish lingual border of
denture:
small sized carbide bur.

 To reduce thickness of palate:

large egg shaped bur.
Coarse abrasives
FINE abrasives
PUMICING PROCEDURES
• A slurry of fine flour of pumice
with water is made.
• The rag wheel is wetted using
the slurry and polished at low
speed.
• In case of less accessible areas a
brush/ prophy cup with slurry is
used for polishing.
• Finally the denture is brushed
with soap to remove all traces
of polishing material.
• Rinse
• Storage - water.
Complete Denture
fabricated
 REFERENCES
• Science of Dental materials by SKINNER
• Laboratory procedure for complete denture
fabrication by RUDD AND MARROW
• Essentials of complete denture
prosthodontics by SHELDON WRINKLE
• Textbook of complete denture by
HEARTWELL