Acrylic Denture Processing and

it’s Principle

Dr. Asheque Rahman

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Denture processing
1: The means by which the denture base materials are polymerized
to the form of a denture.
2: The conversion of the wax pattern of a denture or a portion of a
denture into resin or other material.
(GPT8)

Fig; Flasking
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 Flasking
Denture
A. Half flasking
B. Full flasking Processing
Dewaxing
Application Separating media
Manipulation of heat cure polymer & monomer
Packing
A. Trial packing
B. Final packing

Curing
A. Bench curing
B. Heat curing
Cooling
Deflasking
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Fig: A mold space is made. After heating in hot water, the fl ask is opened,
and the baseplate is separated from the cast.
The baseplate is removed, and the wax is fl ushed out
with hot water while the teeth stay
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• Acrylic resin in the dough stage is placed in
the mold space. The mold is then closed, and
the acrylic resin replaces the wax and base
plate, forming the denture base.

Fig: Mixed acrylic resin in the

dough stage is then placed in the
mold, and the mold is compressed.
While under compression, the
resin is adapted to the master cast
and replaces the baseplate and
wax. The teeth stay in proper
relationship. Finally, the fl ask is
heated, and the resin polymerizes.

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The closed mold is heated in a water bath to
activate the heat-cure acrylic resin. The
heating rate is controlled to reduce porosity.
The application of pressure minimizes loss of
the volatile monomer. Loss of monomer
results in porosity and weak spots.
After processing, the denture is removed from
the mold by breaking the surrounding
gypsum materials.

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  Sealing:
The Denture Is Sealed To The
Cast Preparation
Cast At Its Borders With Molten Wax.

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 Why sealing is done ?

• It Helps To Maintain
Position Of The Denture.

• Mainly Prevents Plaster

From Getting Under The
Denture.

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 FLASKING

• Process by which trial denture is

surrounded by stone / plaster in a metal
flask .
• It basically creates a mould for acrylic
denture.

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 Upper Lid
Middle Half

Lower Half

Flask
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 Selection of flask
Place the dentures and casts in the flask to
check the height of denture teeth in the flask,
To ensure that the flask and the casts are of
compatible size.
4-6mm

4-6mm

4-6mm
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Flasking Technique

• Two Pour
• Three Pour
• Four Pour

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 Three Pour Technique
• Flask.
• 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.
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First pour:
• Separating media is applied at base of sides.
• Stone filled in the lowest portion.
• Seat the prepared cast in the stone filled
lower portion.
• Allowed to set for 20mins.

Second pour:
• Apply separating media over 1stst pour .
• Middle portion of flask is assembled and
pour the 2nd
nd mix till the occlusal surfaces of

teeth and allow to set for 20mins.

• Excess stone is removed to expose cusp tips .

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Third pour:
• Separating Media Is Applied
Again.
• Stone Mix Is Poured Filling The
Remainder Of Flask.
• Allow To Set For 20mins.

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ASHEQUE MS
 Four pour technique

• Similar To 3 Pour Technique.

• A Stone Core Is Built Over The Wax

Surface
Thickness – 2-4mm
Height - 2-3mm Below Occlusal
Surfaces.
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 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
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 Dewaxing
• Eliminates the wax and
temporary denture base for
mould space.
• Place in boiling water for 3-
5mins.
• Excess time in boiling water
causes wax liquify and soak in
stone.
After Dewaxing • Opened flask is flushed with
boiling water to remove
remaining wax.
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 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.

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 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’.
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 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 (wet cellophane paper)
is placed over the dough and 2 halves are closed
with pressure.

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ASHEQUE MS
• 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.

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 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.

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 Bench curing

• Flasks Are Secured In Clamp And Placed Aside

For 30mins.

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 Why?
• Permits equilization of pressure.

• Allows time for uniform dispersion of

monomer.

• Helps in better bonding of tooth with

base material.

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Methods

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 Equipment
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.

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 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.

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Advantages
• Less Risk Of Porosity.

• Less Residual Monomer.

• Indicated For Thick Acrylic

Appliances.

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 Cooling
• Slow Cooling
Bench Cooling.

• Fast Cooling
Bench Cooling For 30mins And Placing It
Under Running Tap Water For 30mins.

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 DEFLASKING

• Removal of denture
from flask using a
wedge instrument.

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 References
•  Complete Denture Prosthodontics by John
Roy Manappallil (ISBN: 9788186809174)
• Dental Laboratory Procedures: Complete Dentures,
Volume 1 by Robert M. Morrow  , Kenneth D.
Rudd , John E. Rhoads (ISBN-13: 978- 0801635199)
• THE GLOSSARY OF PROSTHODONTIC TERMS
• www.youtube.com

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THANK YOU ALL

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