Casting procedures

Dr. Preeti Dubey, Subharti Dental College, SVSU 1

 STEPS INVOLVED IN CASTING PROCEDURE 2

STEP1: Tooth preparation.

STEP2: Impression of the prepared tooth.

STEP3: Pouring the cast to form die.

STEP4: Fabrication of pattern on the die.

STEP5: Preparation of pattern for investment.

• Spruing the pattern.

• Attaching to crucible former.

• Placing in casting ring with liner.

STEP6: Investing the pattern.

STEP7: Burn out.

STEP8: Casting procedure.

STEP9: Recovery of casting, finishing and polishing.

Dr. Preeti Dubey, Subharti Dental College, SVSU 2

 Preparation of DIE 3

• MASTER DIE
Positive likeness of a single tooth made by sectioning the
cast which in turn is made out of an impression

• MATERIALS USED FOR MAKING DIES

1. Gypsum products- Type IV Dental Stone

Type V Dental stone
2. Die stone - Investment combination
3. Electroformed dies- Silver plated
Copper plated
4. Epoxy resins
5. Polyurethane
Dr. Preeti Dubey, Subharti Dental College, SVSU 3
Two fundamental ways to prepare a wax pattern
for a dental restoration: 4

Direct method Indirect method

• In this method, pattern is • In this method, a die of
prepared on tooth directly tooth is first made, and the
in the mouth. pattern is made on die.

Dr. Preeti Dubey, Subharti Dental College, SVSU 4

 Spruing the wax pattern 5

The purpose of attaching sprue former is to provide a channel

through which molten alloy can reach the mold in an invested
ring after the wax has been eliminated.

Sprue
Former

Phillips Science of Dental Materials.,-11th edition.

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Dr. Preeti Dubey, Subharti Dental College, SVSU
 Materials
use for 6
spruing
Sprue
Reservoir former
diameter

VARIABLES AND PRINCIPLES Sprue

Venting former
OF SPRUE FORMER DESIGN attachment

Sprue Sprue
former former
length position
Sprue
former
direction
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Dr. Preeti Dubey, Subharti Dental College, SVSU
 MATERIALS USED FOR SPRUING 7

Wax
•Most commonly used
•Inexpensive
•Easily burn out

Hollow metal
•Used for small inlays
•Stronger than the wax sprue
•Can’t burn out so carefully removed
after investing pattern

Plastic
•Rigid than wax sprue former
• can burn out but may take
longer time than wax to melt
Dr. Preeti Dubey, Subharti Dental College, SVSU 7
 SPRUE FORMER DIAMETER 8

It should be of approximately the same size as the thickest

area of the wax pattern.

Gauge Diameter (in If the pattern is small , spure

mm) former should also be small
because attaching a large sprue
6 4.115
to a thin pattern will cause
8 3.264 distortion and if sprue is too small
this area will solidify before the
10 2.588 casting itself and localize
12 2.053
shrinkage porosity may develop

14 1.628

16 1.291
Dr. Preeti Dubey, Subharti Dental College, SVSU 8
 SPRUE FORMER POSITION 9

Preferred Site of placement are on the:

• Occlusal surface.
• Proximal surface.
• Just below a nonfunctional cusp.

Dr. Preeti Dubey, Subharti Dental College, SVSU

Phillips Science of Dental Materials.,-11th edition.
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 SPRUE FORMER LENGTH 10

Depends on the length of the casting ring.

Top of the wax pattern from open end of the ring should be
6mm- gypsum bonded investment.
• 3mm-4mm - phosphate bonded investment.

Phillips Science of Dental Materials.,-11th edition.

Dr. Preeti Dubey, Subharti Dental College, SVSU 10
 SPRUE FORMER DIRECTION 11

Should be directed away from any thin or delicate parts of the

pattern.
The sprue former should not be attached at a right angle to a
broad flat surface.
Ideally sprued at a 45-degree angle to the proximal area.

Phillips Science of Dental Materials.,-11th edition.

Dr. Preeti Dubey, Subharti Dental College, SVSU 11
 FUNCTION OF RESERVOIR 12

It should be at a distance of 1-2mm from the wax pattern.

It prevent localized shrinkage porosity in the casting.
The resulting solidification shrinkage occurs in the reservoir bar
and not in the prosthesis.

Reservoir

M.A.Marzouk, Operative Dentistry-1st edition

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Dr. Preeti Dubey, Subharti Dental College, SVSU
 Casting Rings and Liners
13
Casting ring is use to invest the wax pattern in the investment
medium.
Types
Metal rings.
Rubber rings.
Split rings.

Phillips Science of Dental Materials.,-11th edition. 13

Dr. Preeti Dubey, Subharti Dental College, SVSU
 14
Ring liners line the walls of the ring to provide investment expansion.

Types
Asbestos sheet.

Fibrous ceramic aluminous silicate.

Cellulose paper.

Ceramic cellulose combination.

GC NEW CASTING LINER.

th edition. 14
Phillips Science of Dental Materials.,-11
Dr. Preeti Dubey, Subharti Dental College, SVSU
 15
Ring liners are placed to ensure uniform expansion in form of
Normal setting expansion.
Semi hygroscopic expansion.

The liner to fit the inside diameter of the casting ring with no overlap.

Phillips Science of Dental Materials.,-11th edition.

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Dr. Preeti Dubey, Subharti Dental College, SVSU
 16

RINGLESS INVESTMENT TECHNIQUE

• With the use of higher-strength, phosphate-bonded
investments, the ringless technique has become quite
popular.
• The method uses a paper or plastic casting ring and is
designed to allow unrestricted expansion.

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Dr. Preeti Dubey, Subharti Dental College, SVSU
 17
Treatment of wax pattern

The wax pattern should be cleaned of any debris, grease, or

oils.
A commercial pattern cleaner or a diluted synthetic detergent
is used.

Synthetic detergent solution

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Dr. Preeti Dubey, Subharti Dental College, SVSU
 18
A pattern should be invested as soon as possible, after it is
removed from the die, and it should not be subjected to warm
environment during this interval.

In any case it should not stand more than 20-30 min before
been invested.

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Dr. Preeti Dubey, Subharti Dental College, SVSU
 Dimensional changes Involved 19

• Dimensional changes occur in most of the steps of LOST WAX technique.

• The final restoration may not be exactly the same size as the pattern.

WAX EXPANSION
+
SETTING EXPANSION
WAX SHRINKAGE +
+ HYGROSCOPIC EXPANSION
METAL SHRINKAGE +
THERMAL EXPANSION

Phillips Science of Dental Materials.,-11th edition.

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Dr. Preeti Dubey, Subharti Dental College, SVSU
 INVESTMENTS 20

DEFINITIONS:

• Invest: To surround, envelop, or embed in an investment

material.

• Investing: The process of covering or enveloping, wholly or in

parts; an object such as a denture, tooth, wax form, crown
etc. with a suitable investment material before processing,
soldering or casting.

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Dr. Preeti Dubey, Subharti Dental College, SVSU
• Classification according to Binders used: 21

• GYPSUM BONDED INVESTMENT – for low fusing alloys

Casting of gold alloys inlays, onlays,
crowns and fixed partial dentures.

• PHOSPHATE BONDED INVESTMENTS: - for higher fusing alloys

Designed primarily for alloys used to

produce copings or frame works for metal
ceramic prosthesis and for some base metal alloys.
It can also be used for press able ceramics.

• ETHYL SILICATE- BONDED INVESTMENTS: for casting of removable partial

dentures with base metal alloys
(cobalt based or nickel based alloys)
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Dr. Preeti Dubey, Subharti Dental College, SVSU
 CASTING PROCEDURE 22

• For casting procedure, we need

Invested pattern
Burnout furnace
Molten metal
Flame sources
Casting machines

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Dr. Preeti Dubey, Subharti Dental College, SVSU
 23
• Once the investment has set for appropriate period of 1hr it is ready
for burn out
• The crucible former and any metal sprue former are carefully
removed.
Any debris from the ingate area are cleaned with a brush.

Crucible former
Dr. Preeti Dubey, Subharti Dental College, SVSU
Removed. Rosenstiel, Contemporary Fixed Prosthodontics. 23
 24

If the burn out procedure does not

immediately follow the investing
procedure, the invested ring is
placed in a humidor at
100%humidity.

If possible, the investment should

not be permitted to dry out.

Plastic vials, as seen here, serves well

as humidor when damp piece of paper
towel is placed on bottom.
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Dr. Preeti Dubey, Subharti Dental College, SVSU
 Wax Elimination and Heating 25

The invested rings are placed in a room-

temperature furnace and heated to
the prescribed maximum
temperature.

For gypsum-bonded investments,

• 7000C for the thermal
expansion technique.
• 5000C for the hygroscopic
technique.

For phosphate-bonded investments,

• 700 to 10300C.

Phillips Science of Dental Materials.,-11th edition.

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Dr. Preeti Dubey, Subharti Dental College, SVSU
 Casting machines 26

Based on the casting processes utilized, different kinds of casting machines

are available today.

• Centrifugal casting machine. Electrical

• High frequency centrifugal casting machine
resistance

• Direct current arc melting machine Induction

• Vacuum pressure casting machine.

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Dr. Preeti Dubey, Subharti Dental College, SVSU
 Methods of Melting the Alloys 27

Generally two methods are employed for melting of metal alloy

prior to casting:

Flame / Blow pipe.

Electrical.

Phillips Science of Dental Materials.,-11th edition.

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Dr. Preeti Dubey, Subharti Dental College, SVSU
 RECOVERY AND FINISHING OF CASTING
28
After the casting has solidified the ring is removed
and quenched in water as soon as the button
exhibits a dull yellow glow.

Advantages of Quenching :
The noble metal alloy is left in an annealed
condition for burnishing and polishing.

When the water contact hot investment, a violent

reaction ensues, resulting in as soft, granular
investment that is easily removed.

Rosenstiel, Contemporary Fixed Prosthodontics 28

Dr. Preeti Dubey, Subharti Dental College, SVSU
 PICKLING 29

The surface of casting appears dark with oxide and tarnish. Such
a surface film can be removed by the process k/a Pickling.
which consist of heating the discolored casting in a acid.

Pickling solution:

Gypsum bonded investment:

50% hydrochloric acid.

Phosphate bonded investment:

cold HF acid.

Phillips Science of Dental Materials.,-11th edition.

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Dr. Preeti Dubey, Subharti Dental College, SVSU
 PRECAUTIONS TO BE TAKEN 30

Casting should not be held

with steel tong.
Gold based and palladium
based metal ceramic and
base metal alloy are bench
cool to room temperature
before casting is removed
from investment and then
subjected to sandblasting,
with fine alumina. Acid is
not use for them.

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Dr. Preeti Dubey, Subharti Dental College, SVSU
 Removal of sprue 31

Remove sprue with

double sided
diamond disc.

Polishing of gold casting is done with carbide burs , green

stones, pink stone, tripoli or rouge.

Polishing of base metal alloy casting is done with aluminum

oxide, tin oxide. th
Phillips Science of Dental Materials.,-11 edition.
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Dr. Preeti Dubey, Subharti Dental College, SVSU