DIE MATERIALS AND TECHNIQUE OF

FABRICATION
CONTENTS:
INTRODUCTION
MATERIALS USED FOR FABRICATION OF DIE
BASIC REQUIREMENTS OF DIE MATERIALS
GYPSUM PRODUCTS
ELECTROPLATED DIES
SILICO PHOSPHATE CEMENT
EPOXY RESIN
METAL SPRAYED DIES
CERAMIC DIE MATERIALS
TECHNIQUE OF FABRICATION OF STONE DIE
CONCLUSION
REFERENCES
1
Introduction
Once the tooth preparation is completed, it is necessary that it be
replicated so that a wax pattern can be developed. Although it is possible to
make the wax pattern directly in the prepared tooth. Such techniques are
difficult to master. Also direct wax patterns are difficult to make it the margins
of the finished cavity preparation extended below the gingival crest or it
visibility is limited. urther more the temperature of the oral cavity tends to
make the wax pattern more susceptible to determination. Also instrumentation
for direct wax pattern is difficult such problems can be eliminated it the wax
pattern is fabricated on a removable die with the removable die finish line
margin of the wax pattern can be carved better.
D!in"tion
A die is a working replica of a single tooth or several teeth.
M"tri"#$ u$d !or !"%ric"tion o! Di:
1. !ypsum products
". #lectroformed dies
- #lectroplated copper
- #lectroplated silver
$. #poxy resins
%. Silicophosphate cement
&. Amalgam dies
"
'. (eramic die materials
). *etal sprayed dies
+he selection of one of this is determined by the particular impression
material in use and by the purpose for which the die is to be used.
B"$ic r&uir'nt$ o! di '"tri"#$
1. Ability to reproduce fine detail and sharp margins.
". ,imensional accuracy and stability - should show little dimensional
change on setting and should remain stable.
$. *echanical properties
a. /igh strength to reduce the likelihood of accidental breakage.
b. Abrasion resistance so that the die can withstand the manipulative
procedures during carving of wax pattern.
%. (ompatibility with impression materials0 +here should be no intraction
between surface of impression and die.
&. !ood colour contrast with other materials being used for ex. 1nlay wax or
porcelain.
'. #conomical
). #asy to use
$
() G*+$u' Product$
+he most commonly used die materials are +ype 12 3dental stone, high
strength. and +ype 2 3dental stone, high strength. improved stones.
Ad,"nt"-$
1. !enerally compatible with all impression materials.
". /ave the ability to reproduce fine detail and sharp margins.
$. ,imensional accuracy and stability are good.
%. 4roduces consistent results.
&. #asy to use.
Di$"d,"nt"-$
Susceptibility to abrasion during carrying of the wax pattern especially
with +ype 12 !ypsum die.
M"nu!"ctur o! T*+ I. "nd . G*+$u' '"tri"#$
,ie materials are based on outoclaved calcium sulphate hemihydrate
plus additives to ad5ust the setting time and pigments for colour contrast.
+o manufacture gypsum die material, calcium sulphate dehydrate is
boiled in $67 solution of calcium chloride or magnesium chloride. +he
hemihydrate particles thus obtained are least porous.
%
!ypsum products used in dentistry are tuned by driving off part of the
/
"
O of crystalli8ation from calcium sulphate dehydrate to form calcium
sulphate hemihydrate.
" (aSO
%
. "/
"
O 3(aSO
%
.
"
/
"
O 9 $/
"
O
dehydrate heat hemihydrate
Sttin- r"ction
:hen calcium sulphate hemihydrate in the form of high strength stone
is mixed with water a chemical reaction takes place and the hemihydrate is
converted back to the dehydrate form of calcium sulphate. +his is an
exothermic reaction.
(aSO
%
. ; /
"
O ; /
"
O (aSO
%
. "/
"
O 9 /eat
+he 1
st
stage in the process is that the /
"
O becomes saturated with
hemihydrate which has a solubility of around 6.<7 at room temperature. +he
dissolved hemihydrate is then rapidly converted to dighydrate which has a
solubility of 6."7 since the solubility limit of dehydrate is immediately exceed
it begins to crystalli8e out of solution the process continues until most of the
hemihydrate is converted to dehydrate.
+he crystals of dehydrate are spherilite in nature and grow from specific
sities called nuclei of crystalli8ation. +hese may be small, particles of impurity
such as unconverted gypsum crystals with in the hemihydrate powder.
&
,iffusion of the (a
"9
and SO
%
"=
ions in to these nuclei also appears to be
important.
As the dehydrate crystalli8es more hemihydrate dissolves and the
process continues.
M"ni+u#"tion
a. Stor"-: 1n closed containers to prevent reaction with moisture from the
atmosphere which can cause formation of the dehydrate which can
accelerate the setting time.
%/ Corrct 0"tr 1 +o0dr r"tio
+o attain maximum strength and resistance to abrasion it is necessary to
use the current /
"
O to powder ratio when preparing dies made of gypsum
products. >educing or increasing w0p ratios, the powder to liquid ratio below
that recommended by the manufactures result in not only reduced strength and
abrasion resistance but also a deviation from the expected setting expansion.
+he w?p ratio for gypsum die materials is 6."" to 6."% i.e. 166 gm of
material is mixed with "" ml of water.
c/ H"rdnin- $o#ution$
(ommercial hardening solutions composed of /
"
O, $67 collided silica
and modifiers may be wed in place of /
"
O. +he amount of solution is less if
'
/
"
O were used alone because surface active modifiers in the hardener allow
the powder particles to be more easily wetted by /
"
O.
@se of hardening solutions affects the hardness and setting expansion of
gypsum die increase in the hardness of high strength stone dies poured against
impressinos are "67 for poly silicons "67 for polysulphide, )67 for agar and
1167 for polyether. /igh strength stones mixed with hardner show a slightly
higher setting expansion of 6.6)7 as compared with 6.6&7 for mixes with
/
"
O alone scraping resistance is also improved high strength stones mixed
with hardener.
S+"tu#"tion: *easured amounts of water and powder are added to a flexible
rubber mixing bowel. +he water is dispensed in the bowl first the powder is
added and allowed to settle in to the water for approximately $6 sec. +his
minimi8es the amount of air incorporated in the mix during the initial
spatulation. A spatulate with a stiff blade is used. Spatulation is carried on by
stirring the mixture vigorously and at the same time wiping the inside surface
of the bowl with the spatula to be sure that all the powder is wet and mixed
uniformly with /
"
O mixing time of one minute is usually sufficient to give a
smooth lamp free slurry.
@se of an automatic vibrator helps the slurry to flow well into the
impression and helps to eliminate the air bubbles over vibration should be
avoided as this may cause distortion of some impression materials.
)
+he time and rate of spatulation have a definite effect on the setting
time and expansion with in practical limites increase in the amount of
spatulation will shorten the setting time. +he setting expansion is also
increased by increase in the rate of spatulation.
Sttin- +roc$$: 1nitially a mix of hemihydrate and /"O can be poured.
Aext the material becomes rigid but not hard this is called initial
setting. At this stage the material can be carved but not moulded.
+he final set follows when the mix becomes hard and strong.
/owever at this stage the hydration reaction is not necessarily complete
nor has optimum strength and hardness necessarily been achieved.
/eat is given out during setting since the hydration of the
hemihydrate is exothermic.
,imensional changes also takes place. A setting expansion of 6.6& -
6.$7 is observed for dental stones. +his is caused by the outward thrust
of the growing crystals of dehydrate. 1f the material is placed under water
at the initial set stage a greater expansion on setting occurs. +his is
hygroscopic expansion.
<
Pro+rti$
1. 1nitial and final setting time
+he initial setting time is also called the working time. ,uring the
working time the material can be mixed and poured in to the impression.
As the chemical reaction proceeds more and more dehydrate crystals
form. +he viscosity of the reacting mass increase rapidly and the mass no
longer flows into the fine details of the impression. At this point the material
has reached the initial setting time and should no longer be manipulated.
1nitial setting time can be defected clinicaly by a phenomenon known as
loss of gloss.
+he initial setting time must occur with in <=1' minutes from the start
of the mix. +he final setting time is defined as the time at which the material
can be seperated from the impression without distortion or fracture. +he time
at which the chemical reaction is practically completed. +his is usually
measured as the time taken for the setting material to become sufficiently rigid
to withstand the penetration of a needle of known diameter under a lesser load.
+wo such pieces of apparatus or known as vicat and gillmore needles.
i/ Contro# o! $ttin- ti' !"ctor$ undr t2 contro# o! '"nu!"ctur$
(oncentration of nucleating agents in the hemihydrate powder
increase nucleating agents decreasing setting time. #x. ,ehydrate particles.
B
Addition of accelerators and retarderes accelerators used are C
&
SO
%
and 3(aSO
%
. /
"
O crystals. >etarders - "7 Dorax.
!rinding of gypsum product during manufacture accelerates the
setting 3grinding increase the surface area of the hemihydrate exposed to
water. +hese increases the rate of solubility of hemihydrate..
ii/ F"ctor$ undr t2 contro# o! o+r"tor
:ater ? powder ratio.
1ncrease w?p ratio retards the setting by decreasing the concentration of
nuclei of crystalli8ation.
Mi3in- ti': An increase in the mixing time an accelerates the set.
*ixing can break up some of the formed dehydrate crystals these forming
more nuclei of crystalli8ation.
(olloidal septems such as blood, saliva can retard setting time.
T'+r"tur
+emperature variation has little effect on the setting time on increase
from a room temperature of "6E( to a body temperature of $)E(. +he rate of
the reaction increase slightly and the setting time is shortened. As the
temperature is raised above $)E( the rate of reaction decrease and the setting
time is lengthened.
16
4) R+roduction o! dt"i#
!ypsum dies do not reproduce surface detail as well as electroplated or
epoxy dies because the surface of the set gypsum is porous on a microscopic
level. +he porosity of the set gypsum causes the surface to be rough compared
with other die materials.
+he use of a hardener solution instead of water during mixing may
reduce surface roughness. Air bubbles frequently are tuned at the interface of
the impression and stone because the freshly mixed gypsum does not wet some
impression materials well.
5) Co'+r$$i, $trn-t2
+he strength of gypsum material is directly related to the density of the
set mass because high strength dental stone is mixed with the least amount of
/
"
O it is the densest of the gypsum materials and the strongest. +he 1 hour
compressive strength of high strength dental stone is %B<6 psi.
6) Tn$i# $trn-t2
1t is $$6 psi it is a brittle material and is considerably weaker in tension
than in compression.
7) H"rdn$$ "nd "%r"$ion r$i$t"nc
11
+he surface hardness is related to the compressive strength. +he higher
the compressive strength of the hardened mass the higher the surface hardness.
+he hardness of gypsum die material is $ times that at an epoxy die but
hart that of an electroplated die. +hough it is the most resistant of the gypsum
materials to abrasion.
+he use of a hardening solution in place of water may increase hardness
and improve abrasion resistance as a result of a smooth surface.
8) Di'n$ion"# "ccur"c*
All gypsum materials show a measurabe liner expansion on setting. +he
expansion result from the growth of the (aSO% "/"O 3dehydrate. crystals and
teir impingement on one another. /igh strength stone has a setting expansion
of about 6.617 to 6.6<7.
+his expansion of the die material compensates for the casting
shrinkage of the metal.
>ecent developments
+wo techniques have been investigated to produce dental stone with
improvement in abrasion resistance and other mechanical properties.
1"
a. 1mpression of the gypsum by a polymer like polyether, polystyrene, acrylic
or epoxy resin. A solution of 167 polystyrene in amyl acetate can be
painted on to the surface of the die the excess blown off and then allowed
to dry for about & min mineral oils like ,erusil can also be used.
b. 1ncorporation of setting agents such as lignosulphonates can reduce the
/
"
O requirements of a stone and enable the production of a harder,
stronger and more dense set gypsum.
+hese aditives retarded the setting time and increase the setting
expansion 3Doth of these effects can be overcome by the incorporation of
C
&
SO%..
Di $ton9 In,$t'nt co'%in"tion
1n this the die material and the investing medium have a comparable
composition. A commercial gypsum bonded material called divestment is
mixed with colloidal silica liquid. +he die is made from this mix and wax
pattern constructed on it then the entire assembly 3,ie 9 4attern. is invested in
a mixture of divestment and water, thereby eliminating the possibility of
distoration of the pattern on removal from the die or during the setting of
investment. +he setting expansion of the material is 6.B7 and thermal
expansion is 6.'7 when heated to '))E(. because divestment is a gypsum
bonded material it is not recommended for high fusing alloys like metal
1$
ceramic restorations. 1t is highly accurate technique for conventional gold
alloys especially intracoronal preparations.
,ivestment phosphate is a phosphate bonded investment that is used in
the same manner as divestment and its suitable for use with high fusing alloys.
II) E#ctro+#"td di$
*etal dies can be made by copper plating compound impression or
silver plating rubber base impression when a die is made in this manner the
process is referred to as electroplating.
Ad,"nt"-$ o! #ctro+#"td di$
1. :ith materials such as gypsum products dimensional change may occur as
the die material sets. Ao such expansion or contraction occur with
electroformed dies unless the impression material shrinks before the initial
plating is deposited.
". #lectroformed dies have higher strength hardness and abrasion resistance.
$. Allows satisfactory finishing and polishing of metal restoration on the die.
Di$"d,"nt"-$
1. +ime consuming
". Special equipment is needed
$. Aot compatible with all impression materials.
1%
Co++r +#"tin-
(opper plated dies are most commonly made from compound or
addition silicone rubber impressions.
+he popularity of copper plated compound dies began in the early
1B$6Fs.
+he first step in the procedure is to treat the surface of the impression
material so that it conducts electrically. +his process is referred to as
metalli8ing.
+he surface of the impression is rendered conductive by coating it
with fine particles of copper or graphite.
+he coated impression is made the cathode 3=ve electrode. and
electrolytically pure copper plate is attached at the anode. Doth anode and
cathode are immersed in an electrolytic solution continuing an acidic
solution of copper sulphate 3about "&6 g1G. together with organic
constituents like alcohol or phenol. :hich are believed to increase the
hardness of the deposited metal.
A current is passed of 1& miliampher? cm" of cathode surface for
approximately 16 hours. +his cause slow dissolution of the anode and
1&
movement of copper ions from anode to cathode this plating the
impression.
+he impression that contains the electrotuned die surface is then
filled with dental stone. :hen the stone hardens it is mechanically locked
to the rough interior of the electroformed metal shell. +he impression
material is then removed to provide a die with greater surface hardness and
resistance to abrasion than that of gypsum.
Si#,r +#"tin-
1ndicated for polysulphide polyether, and silicon rubber impression
materials.
+he process of silver plating is similar to that of copper plating but a
smaller current of & miliamphes is sufficient.
+he impression is coated with silver or graphite powder is made the
cathode.
Anode is silver plate.
+he electrolyte is an alkaline solution of silver cyanide 3$6 gm. with
other constituents like potassium 3'6 gm. cynide and potassium carborate
3%& gm. in distilled water 31666 ml..
Prc"ution: care must be taken to avoid the addition of acids to the cyanide
solution. :hich can cause the release of cyanide vapor a death chamber gas.
1'
(opper plating should not be done in the same area. 1n which silver
plating is done because the risk of contamination the silver plating solution
with acidic copper plating solution.
A'"#-"' Di$
+hey are made by packing amalgam into impression made of
impression compound.
Ad,"nt"-$
,ies made of amalgam exhibit superior strength resistance to abrasion
and reproduce fine details and sharp margins.
Although a material of choice a number of years ago it has been largely
replaced by electroplated dies. :hich are also resistant to abrasion the
property of amalgam dies has declined for a number of reasons.
1. 1t can be packed only into a rigid impression like that of impression
compound.
". 3Decause of the tech necessary to produce a sound die. dimensional
accuracy may vary from one die to the next.
$. +ime required for fabricating an amalgam die is lengthy. Although the die
packing procedure may take only $6 minutes amalgam requires 1" to "%
hours of hardening before it can be manipulated as a die.
1)
%. 1t has high thermal conductivity and so can cool a wax pattern rapidly
which may lead to distraction of the pattern. +his can be overcome by
warming the die.
I.) Si#ico +2o$+2"t c'nt
1t is similar to the filling and cementing material. +he powder is a
mixture of silicate powder and 8inc oxide liquid contains phospheric acid.
Ad,"nt"-$: Strength and surface hardness are superior to those of die stone.
Di$"d,"nt"-$: +his material contracts during setting and may be
dimensionally inaccurate. +here is loss of water on standing since the viscosity
of these material is relatively high. 4resence of surface voids can occur.
.) E+o3* r$in :+o#*'r$/
+hese are either self curing acrylic materials for #g. #poxy resins, poly
yesters and #pimines or polymeric materials with fillers 3either metallic or
ceramic fillers..
Ad,"nt"-$
1. *ore abrasion resistance.
". Gess brittle than die stones.
$. (an be carved at room temperature.
1<
Di$"d,"nt"-$
1. Shrinkage on polymeri8ation
". Gess dimensional stasility
$. #xpensive.
#poxy die material can be used with polyether, polysulphide or silicone
epoxy to which filler may be added.
(/
"
- (/ - > - (/ - (/
"
O O
+he hardner is a polyamine that when mixed with the resin for about a
minute causes polymeri8ation. +he hardness is toxic and should not come into
contact with the skin during mixing and manipulation of the unset material.
Pro+rti$
1. :orking time - 1& min.
". Setting time - 1 to 1" hours depending on the product.
$. Cnoop hardness number is "& C/A H1& less than that of high strength
stone 3)) C/A..
%. (ompressive strength after ) days is 1',666 psi.
&. Abrasion resistance is superior to stone dies.
'. ,imensional change due to shrinkage during polymeri8ation is between
6.6$7 and 6.$7 and continues to occur for upto $ days.
1B
). #poxy materials are very viscous when poured hence porosity can occur.
<. #poxy resin cannot be used with water containing agar and alginate
materials because water retards the polymeri8ation of the resin. they are
compatible with polyether, polysulphide or silicon impression materials.
.I) Mt"# $+r"*d di$
A bismuth - tin alloy which melts at 1$<E( can be sprayed directly on
to an impression to form a metal shell which can than be filled with dental
stone.
Ad,"nt"-: A metal coated die can be obtained rapidly from elestomeric
impression materials.
Di$"d,"nt"-$: +he alloy is soft, care is helded to prevent abrasion of the die.
.II) Cr"'ic di '"tri"#$
+wo ceramic die materials are available
1. A material for the production of dies on which porcelain restorations are to
be fabricated without the use of a platinum foil matrix. +o form the dies
heating to over 1666E( 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 '66E( for < min to produce a hard stone die.
"6
Tc2ni&u o! !"%ric"tion o! $ton di
After the impression has been removed from the patients mouth it is
washed under running tap water blown dry inspected and disinfected.
+he dowel pin should be positioned correctly over the prepared tooth
with the help of pins and sticky wax. +heir correct location and orientation is
important. or example placing the head of a dowel too deep in the impression
may weaken the die positioning the dowel at an incorrect angle may make die
removal impossible.
1. @sing the right w?p ratio mix +ype 12 or 2 stone with water.
". 4ick up a small amount of stone with a suitable brush or instrument and
place it in the most critical area.
@sually the occlusal aspect of narrow preparations or immediately
ad5ust to the sulcus area. Dubbles will be trapped it to much stone is added
abruptly.
,uring powering the tray should be held on a vibrator.
$. Slowly release the stone into the preparation along the axil walls by tilting
the impression and guiding the material with the instrument. De absolutely
sure that the stone flows onto the margins of the preparation without
trapping any air bubbles.
"1
%. 4lace a second amount of stone on top of the first and continue with a third
and so forth until the preparation is completely filled the rest of the
impression is then filled and the head of the dowel must be covered with
stone.
&. 4lace retentive devices in areas where there are no dowels so the two layers
of stone will not separate in the wrong places.
'. Allow the stone to set.
). 1nspect the area where separation is required. Smooth it as necessary and
cool it with a separating medium by 167 sodium silicate. +hen pour
another layer to act as a base and retain the dowel. +his second layer
should not cover the tip of the dowel to facilitate its retrieval later.
<. :hen the cast is separated from the impression it must be inspected for
voids. 1t found to be satisfactory it is ready for sectioning and trimming.
B. +rim the buccal and lingual sulcus area ad5acent to the removable section
first so the die will separate cleanly.
16. *ark the position of each saw cut which should be parallel to the dowel
with a pencil.
""
11. (arefully insert the saw blade between the preparation and the ad5acent
tooth being sure that neither the margin nor the proximal contact is
damaged.
+he cut must pass completely through the first layer of stone once the
saw cuts are made the dies can be separated out and are ready for trimming for
waxing.
@pon completion of die trimming the dies are repositioned in the
master cast and it is verified that they can be repositioned accurately and
precisely.
Conc#u$ion
All factors considered the high strength stones 3+ype 12 and 2.
appear to be the most successful die materials available with care abrasion
during carving of the wax pattern can be avoided. 1n case of metal ceramic
restorations gypsum dies can be damaged. /ence a resin or metal die may be
prepared
"$
REFERENCES:
undamentals of fixed 4rosthodontics0S2i##in-%r-)
(ontemporary fixed 4rosthodontics 0
o St+2n F)Ro$n$ti#
4hilipFs science of dental materials :Anu$",ic
,ental material =properties and manipulation 0
o Cr"i- ;+o0r$
Aotes on dental materials= E C Co'%
>estorative dental materials= Ro%rt G Cr"i-
P2i#i+ Du< t "# I4hysical properties of type 12 gypsum, resin
containing and epoxy die materials J4, April "666 vol <$, no. %
p=%''=)$.
="cint2 M t "# in 4>>> dimensional accuracy of an epoxy resin
die material using two setting methods. J4, *arch "666 vol <$
no$ p $61=$6&
"%
A SEMINAR ON
DIE MATERIALS AND TECHNIQUE OF
FABRICATION

Presented by
Dr)U)."r"#"<$2'i SIGNATURE OF H)O)D
P)G Studnt
D"t:
D+t) O! Pro$t2odontic$
SIBAR In$titut o! Dnt"# Scinc$
GUNTUR
"&
"'