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DEFINITIONS:
Cast:- A dimensionally accurate reproduction of a portion of the oral cavity and extra
oral facial structures produced in a durable hard material and used as a base for
construction of orthodontic and prosthetic appliances.
Die:- The positive reproduction of the form of a prepared tooth in any suitable hard
substance, usually in metal or specially prepared artificial stone.
Model:- A facsimile used for display purposes; a miniature representation of
something; an example for imitation or emulation.
PREREQUISITES:
Cast: It should be free of defects.
It must reproduce both prepared and unprepared surfaces.
Unprepared tooth immediately adjacent to the preparation must be free of
voids.
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Dr. Vinni T.K
MATERIAL SCIENCE
The materials available for making dies are numerous and range from stone to
metal, resin and cement. The successful production of dies is to a considerable extent
dependent upon choosing a die material that is suitable for a particular impression
material.
REQUISITES:
1. Dimensional Stability:They should not expand and contract or distort after pouring into the
impression under normal storage and use.
2. Accuracy:51
1.
2.
3.
4.
5.
6.
Dimensional stability.
Dimensional accuracy expansion 0.1 % or less.
Surface reproduction is adequate.
Relatively inexpensive.
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ii)
iii)
iv)
Disadvantages:
Application of die spacer is difficult.
Sending divestment cast for interocclusal records may be problematic.
The die will be destroyed, hence, second cast & die material must be
made to permit finishing and polishing.
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In the last few years, gypsum die stones have been compounded with resin to
provide the advantage of each material. These modified die stones maintain the low
expansion of stone and toughness and abrasion resistance of resin. E.g. ResinRock
( Whipmix Corporation). They have high strength and and low expansion, and are
particularly suitable for casts for implant restorations.
3. ELECTROFORMED DIES
Electroplating can be defined as the process of covering the surface of an
object with a thin coating of metal by means of electrolytes.
Review of literature:
The German scientist Jacobi laid the groundwork in 1837 for industrial and
dental electroforming. Electroplating activity in fixed prosthodontics and restorative
dentistry started in the early 1930s with the introduction of modelling compound
copper plated dies. Hydrocolloid was the first elastic impression material to be used as
a substrate for obtaining electroformed copper dies in the 1950s. However it proved
to be unstable and hence its usage declined. The initial enthusiasm for copper as an
electroplating metal soon faded and silver became the metal of choice with the
introduction of mercaptan rubber. But soon after the dimethyl siloxane impression
material appeared both copper and silver were reported as acceptable die materials.
Procedure:
The basic system consists of an electrolytic solution of CuSO 4, or AgCN and a
source of direct current. The anode is either pure Cu or pure Ag. The surface to be
electroplated is the cathode. Generally, Cu plating is used for compound impression
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and Ag plating for poly sulphide impression. Silicone impression materials by virtue
of their low surface energy are difficult to electroplate.
1.
Clean and dry the impression and coat the surface to be electroplated with
metallising powder like Ag powder or graphite.
2.
Direct the cathode wire in the border of the impression in the metallised areas
but not too close to preparations.
3.
Fill the preparations and teeth with electrolytic solution with eyedropper to
prevent air bubbles and voids and completely immerse the impression in the solution.
The Ag anode immersed in the solution should be at least equal in size to the area of
the surface to be plated.
4.
Proceed with the plating initially at approximately 5 mA per tooth for 1 hour
and examine the impression after 1 hour to check for deposition of metal and to make
certain there are no voids. Resubmerge the impression in the plating solution, plate
for12 hour at 10mA per tooth.
5.
After completion of electroplating, wash the impression and use dental stone as
a backing material.
Advantages:
i.
ii.
Disadvantages:
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i.
ii.
iii.
iv.
Electroplating unit for silver and copper plating of impressions This electroplating unit allows you to
electroplate impressions in as little as 3 to 6 hours. The system ensures an even and homogenous
deposition of silver or copper and offers high stability whilst providing ideal coverage on both large
and small surface areas.
4. AMALGAM
Amalgam dies are used with copper band modelling plastic impression. The
impression has to be wrapped in wax or tape and embedded in a rigid matrix such as
plaster to resist the pressure necessary to condense the amalgam effectively.
Disadvantage:
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shell which is subsequently backed up with self-cure acrylic or stone. Suitable for
polysulfides and silicones. Difficult to spray in narrow confined areas. The fine spray
is injurious to health.
2) Ceramic Die:
Diamond die, Ceramco die
Supplied in powder and liquid. When mixed it has a putty like consistency. The
initial set is reached after 45 minutes, when care is needed while removing from
impression as the material is weak at this stage. To obtain maximum hardness it heated
in a oven at 600C for 8 minutes and **** in light mineral oil. The material is suitable
for use with flexible impression materials such as polysulfide or silicones. Dies with
well-defined margins can be made quickly with experience.
3) Cement Dies:
Model Kryptex
It is supplied as a powder and liquid. The mixing and working properties are
similar to those of dental cements. It can be used successfully with any impression
material.
Sharp well-defined margins are reproduced. Flow properties are good when
assisted by vibration. Dies can be produced in an hour. If the material is allowed to dry
out, it becomes brittle. Die when not in use can be placed in to liquid paraffin or light
mineral oil.
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Procedure:
Impression is poured in Type IV stone in the area of preparation(s) only. When
set, it is separated and a second pour is made of the entire arch.
The first pour is trimmed into a die with a handle of sufficient length (similar to
a tooth root). The complete arch cast is mounted on an articulator. The wax pattern is
started on the initial pour (the die) and is then transferred to the articulated cast for
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refinement of axial contour and occlusal anatomy. When completed, this pattern is
returned to the die so the margins can be readapted immediately before investing.
Die Preparation:
The handle of the die should be slightly larger in diameter than the preparation
and octagonal in cross-section. Its side ought to be parallel or slightly tapered toward
the base. Handle should be parallel to the long axis of the tooth preparation. The
handle should be approximately 1 inch long.
A pear shaped acrylic bur to trim the die apical to the finish line of the
preparation. Begin final trimming of the die with a sharp no.25 blade. The area apical
to the finish line should be smoothed and made free of ridges with the discoid end of a
Tanner carver.
The contour of the die apical to the finish line should approximate that of the
root to facilitate good axial contours in the finished restoration.
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Sharply undercutting or ditching the die below the finish line is not advised.
Because the instrument used for finishing the margin of the wax pattern will rest
against this portion of die, acute angulations can be exaggerated by undercuts. This
will result in a thick gingival area on the restoration and an axial contour that is not
conducive the good gingival health.
After the die has been trimmed, the finish line should be highlighted with a
sharp colorbrite red pencil. Do not use excessive pressure when marking the finish
line as it may be rounded over. A black graphite pencil should not be used for this
purpose. When used with usual blue or green wax, a finish line outlined in black does
not become more visible, but instead makes every wax
unsealed or open. In addition, remnants of clay binder used in graphite pencil could
contaminate the margin of the casting.
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Procedure:
1. The position of the dowel pin is located and marked in the impression.
2. Dowel pins are positioned over the impression with bobby pin /wire and
stabilize the bobby pin to the impression with straight pin and sticky wax.
3. Pour die stone in the impression, filling the impression of the teeth and
covering the knurled end of the dowel pin. Pin should parallel the log-axis of
the preparation and it must not touch impression.
4. Paper clips can be added to non-removable parts of the unset first pour to
provide retention for the second pour of stone.
5. When the stone has set, remove the straight pins and bobby pins from the
impression. Place a small ball of soft utility wax on the tip of each dowel. Cut a
v-shaped buccolingual orientation groove or a round dimple on each die to aid
in reseating the die completely and accurately during use. Lubricate the stone
around each dowel with a thin coat of petrolatum. Remove excess lubricant.
6. Seal the open lingual space with wax or paper towel. Box the impression and
pour the stone.
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7. When stone sets, remove the cast from impression and trim the excess with a
model trimmer.
8. Wax at the ends of the dowel pins are located and removed. Allow the stone to
harden for 24 hours.
9. When the stone is hard and dry use a saw to cut through the layer of die stone.
There should be a cut on the mesial and distal side of each die and the cut
should taper towards each other from occlusal to gingival. Gently tap on the
end of the dowel with an instrument handle to loosen the die.
10. Die trimming should be done as discussed previously.
11. Reseat the dies to make certain that they will seat completely and will be
stable.
12. Place utility wax back into the wells around the tips of the dowel to protect
from plaster contamination. Soak the cast in water and mount it on the
articulator using mounting stone. When the stone has se, remove the wax
covering the tips of the dowels. Make certain that no chips of stone or wax are
left in the wells.
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C Straight pins
B Positioning bar
After the stone has hardened, make vertical saw cuts on either side of each die.
Separate each segment from working cast by pressing or tapping on the protruded tail
of the curved dowel with a knife or handle.Placing pin in prepared cast is similar to
Pindex system.
3. Pindex System:
(Coltene / Whaledent International Newyork NY)
model trimmer to trim excess cement from the periphery. Remove excess stone from
the palatal / tongue area with the help of a palatal trimmer or with an arbor band on a
lather. The lingual border of cast should taper slightly towards the base to facilitate
removal of dies from the cast later.
Mark the desired locations of pins on the occlusal surface. There should be two
pins for each die. Two for each pontic area and two pins in each terminal segment
containing unprepared teeth.
Place the prepared cast on the worktable and align the first pencil mark with the
illuminated dot from the light beam director. Using both thumb and index finger
stabilize the cast on the table and press the table downward slowly. This enables the
drill assembly to move upward and cutting the pinholes. Release the hand and the
table will come upward. Repeat the procedure for other holes. Use compressed air and
brush to remove debris from the pinholes.
Prior to cementation, try-in the pins to insure complete seating. The collar of
pin should be flush with the base of the cast to avoid creating an undercut.
Cyanoacrylate cement can be used to lute the pins in their holes. The cast must be
thoroughly dry before cementation. Place the sleeves on the pins.
Apply a thin coat of petrolatum to the bottom of the cast. Wipe of excess with a
cotton roll. Run a strip of utility wax along the ends of long pins to facilitate removal
of dies.
Pouring of base can be done by boxing the cast or by using specially designed
base formers. Care should be taken to avoid void formation around the pins. Add a
small amount of stone to the bottom of the cast in the area of pin and carefully vibrate
between pins. Invert the cast and seat it slowly in the base former until the wax on the
ends of the pins contacts the bottom of the mould. Allow the stone to set.
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Pinned casts can be removed from the base in one piece, which permits
sectioning of the cast into dies from the underside and thus reduce the damage to the
finish lines. After dies are sectioned, trim them in the conventional manner.
Advantages:
1. Final impression is poured immediately and without the disadvantages of
pins suspended to the impression.
2. The removable sections are planned with the finished master cast rather than
the impression.
3. Dies can be sectioned from the under side of the cast, reducing chances of
damaging the stone at the finish line
4. Double pinning with parallel pins for each die improves accuracy and
stability.
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Tri-Plus Pins.
During the placing of pins anti rotation grooves should be placed. Now Dowel
Pin Indexers are also available. Indexers work with most dowel pins to provide antirotational stability and color coded location for removable dies.
4. Di-Lok System:
This is a snap-apart plastic tray with internal orienting grooves and notches and
can be used to reassemble the working cast and die. Like all removable die systems,
great care must be taken to keep it clean so that the parts will fit together with the
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greatest possible accuracy. Before using the tray, examine the mounting of diagnostic
casts on the articulator to determine whether there is space for the bulky tray.
Pour the entire full arch impression with die stone approximately inch height.
Trim the palatal / lingual and buccal sides to make sure the U-shaped cast to fit into
DI-LOK tray. Score the base of the cast with a separating disc in a straight handpiece.
Place one or two horizontal grooves on the inner and outer aspects of the cast to
provide undercuts for holding the cast in stone in the tray.
Soak the base of the cast in water for about 5 minutes. Mix stone and vibrate
into the tray until the tray is filled to . Seat the cast into the tray jiggling it slightly as
it settles to eliminate bubbles. The cervical lines of the teeth should be about 4 mm
above the edge of the tray when the cast has been seated. Wipe of the excess stone and
allow it to set.
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After separating the cast from the tray saw cuts are made
on each side of the prepared tooth to separate it from the cast. The die is trimmed
apical to finish line with an acrylic bur.
Check the tray for any stone flush and remove it with compressed air and stiff
brush. When the tray is completely clean, reassemble the dies and other parts of the
cast in the tray and lock the tray in the reverse order.
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To attach the Di-Lok tray to the articulator, put the mounting stone on the
articulator ring and on the bottom of the tray, which has undercut rails on it.
9. The refractory die duplicated the master die in relation to other teeth as well as
in configuration.
Alternative Die Systems:
The DVA model system and the Zeiser model system use a precision drill and
special baseplates that are aligned and drilled to provide die removal. These systems
offer the advantage for the expansion of stone which is relieved by the saw cuts.
DVA Model System:
Cast is sectioned
The pin locations are determined and the pinholes are drilled into the base
The cast is separated from the impression when set and then separated from the base.
Dry trimming of the dental arch iun the vestibular area and palatal area.
SELECTION OF SYSTEM:
Several methods for preparing separable dies are discussed here. The selection
of any of these systems depends upon the technical skill and experience, as the
principal disadvantages of a removable die system is the risk of introducing error in
the pattern if the die does not reseat accurately in the working cast.
Single dowel are simple to use, but they do not provide anti-rotation resistance
as double dowels. Pindex systems with double pins provide excellent stability and
reduce the chance of damaging the finish lines. But they require costly equipments.
FUTURE TRENDS:
The current available die systems are working with satisfactory result.
However, the preparation of a die is a tedious procedure. Research should be directed
to simplify the procedures involved in fabrication of these systems. With the
introduction of stronger and durable direct restorative material, the necessity for
indirect fabrication can be reduced. With the advent of CAD-CAM system the whole
impression procedures and die preparations is eliminated. Successful restorations with
minimal visits and laboratory procedures can be fabricated in metal and ceramic.
However, this system has to be developed more to compete with conventional
technique.
The future of die systems is not promising. The invention of durable and
esthetic direct restorative material may effectively reduce the number of indirect
restorations.
CONCLUSION:
Accurate working cast and dies are essential in making successful cast
restorations. Different materials and technique are available that give extremely
precise reproduction of the prepared tooth. The choice of working cast and dies
depend upon the advantages and disadvantages of each method and operators
preference. If done carefully all the available systems are capable of achieving
clinically acceptable results.
REFERENCES:
5. ANUSAVICE K.J:
Philips Science of Dental Materials.
( 10th Edition, W.B. Saunders Co.)