Applied material Level 2

Model and Die Materials

Model It is a positive reproduction of the teeth and associated tissues of the jaw which is
= cast prepared from an impression.
Die It is a model of a single tooth

 Indication of model & die:

1.dignosis from lingual view
2.manfucturing of indirect restorations
3. manufacturing of retainers & night guard in ortho
4. pt. education &dental research

• Ideal Requirements of Model and Die materials

a) Accuracy:
1. must reproduce an impression fine details accurately
2. dimensional stability & no expansion or contraction during or after setting
3. Be dense(non-porous )and smooth surface to produce a smooth
surface in the restoration which is placed upon the tissue surface.
b) Mechanical properties:
1. High compressive strength to reduce accidental breakage
2. Hardness : to withstand scratching by carver during wax pattern
manufacturing
c)Practical to use:
1. They should be compatible with impression materials. There should be no interaction between
surface of impression and model or die.
2.Good color contrast with impression materials & inlay wax
3. Cheapness and ease of use.
4.suitable working time & short setting time
• Materials used for model and die:
1. Gypsum products.
2. Resin:
a) Epoxy resin
b) Polyurethane
c) Flexible die material

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3. Electroplated dies.
a) Copper plated
b) Silver plated
4. Metal sprayed dies.
5. Amalgam dies.
1. Gypsum products (Dental Plaster and Stone)
• . Types of Gypsum Products: There are five types of gypsum products:
Type I. Impression Plaster.
Type II. Model Plaster.
Type III. Dental Stone, model (hydrocal).
Type IV. Dental Stone, die, High Strength (Densite).
Type V. dental stone , High Strength, High Expansion
• Nature of the gypsum:
▪ Gypsum is available in the form of calcium sulphate dihydrate (CaS04.2H20). It is white in color,
and known as Alabaster.
▪ Gypsum products are the same calcium sulphate hemihydrate (CaS04.2H20) but they differ in:
1. Method of production.
2. Particle size and shape.
3. Water/powder ratio.
4. Physical and mechanical properties.
5. Uses.
1. Methods of Production (Calcination):
▪ Calcination: the process of removing the water of crystallization from the dihydrate
▪ The gypsum is ground and subjected to temperatures, to drive off part of the water of
crystallization.
(Ca S04)2.H2O + 3H2O heat 2CaSo4.2H2O + (unreacted (CaSo4)2 .1/2 H2O +Heat
hemihydrate + water dehydrate + unreacted hemihydrate + heat
▪ Depending upon the way this part of water is driven off, we get the form of the hemihydrate
1) dry calcination 2) wet calcination 3. wet calcination in
autoclave
Result Plaster of Paris or β- Dental Stone or α Modified α calcium sulfate
material hemihydrate: (Type I hemihydrate: (Type III) hemihydrate = die stone =
and II) (hydrocal) High strength stone= type IV
&V
Method prolonged heating of heating gypsum at 110° C- - heating gypsum under
gypsum at 110-130 °C 130° C in an kettle under pressure in autoclave in
in open air. steam pressure. boiling 30% solution of Ca Cl2
or MgCl2. Or more than 1%
sodium succinate
- Then the chlorides are
washed with boiling water.
Character of porous(spongy) and uniform in shape , prismatic - the densest of the three types
powder irregular in shape & and denser than the plaster and the hardest after setting.
large particles of Paris. - cube shaped
-Reduced surface area
- dense

1. Ca S04.2H20 110-130c β CaS04.1/2H20 + 1.5H20.

Open air

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2. Ca S04.2H20 120-130 ° C αCaS04.1/2H2O + 1.5 H2O

autoclave under steam pressure
3. CaS04.2H20 in boiling 30% solution of Ca Cl2 or MgCl2 α CaS04.1/2H2O + 1.5 H2O
Closed kettle or autoclave

2.Water/powder Ratio:

• Essential water: amount of water required for chemical reaction to occur & it is the same for all
types
• Excess water (free water): amount of water needed to produce a workable mix and produce fine
details & it is variable between materials.
• Manipulation water is different while chemical water are the same
• Theoretically: each 100 gm powder of plaster or dental stone requires only 18.6 ml. water to
complete the chemical reaction. (essential water / water for crystallization)
• Any amount of water greater than this amount is excess water which contributes to the reduction
in strength and hardness.
• However, water in excess is required to make the mix workable. This excess water evaporates,
leaving pores. It may take about 7 days to lose the excess water (dry strength).
• Water requirement of a product is affected by:
1. Shape and compactness of crystals: irregular, spongy plaster particles need more water than
the denser stone.
2. Small amounts of surface active materials like gum Arabic& calcium oxide (0.1%) plus time
markedly reduce water requirement of all gypsum products.
3. Particle size distribution : Grinding of the powder breaks up needle like crystals. This improves
packing characteristics and reduces the water needed
• the amount of water necessary to make a workable mix as follows:
1) Plaster: 100 gm powder need 50 ml. water.
2) Stone: 100 gm powder need 30 ml. water.
3) High strength stone: 100 gm powder need 22-24 ml. water.
4) High strength high expansion stone : 100 gm powder need 18-22 ml water
Setting Reaction of Gypsum Products:
▪ When hemihydrate is mixed with water, the reaction is reversed and the dihydrate is formed.
CaS04.1/2H20 + H2 0 CaS04.2H20 + unreacted hemihydrate +heat

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▪ The reaction is exothermic and the heat evolved is equivalent to the heat used originally in the
calcination of gypsum. This chemical reaction is the same in all types of gypsum.
▪ Set gypsum products probably never attain 100% conversion at room temperature ( always have
unreacted particles ?? as water cant cause conversion to all hemihydrate)
 Mechanism of Setting:
▪ 3 theories have been proposed:
1. Colloidal theory
2. Hydration theory
3. Dissolution -precipitation theory (crystallization)
Dissolution -precipitation theory (crystallization)
 Based on the fact that : The solubility of the hemihydrate in water is much higher than the
formed dihydrate near root temperature
 Steps:
On mixing hemihydrate with water, the following are believed to occur:
1.Some of the hemihydrate dissolves in water to form Ca++and S04 ions supersaturated in
solution.
2.The solubility of the hemihydrate in water is much higher than the formed dihydrate.
3. As the reaction proceeds rapidly, the concentration of the dihydrate increases and the solution
becomes supersaturated.
4. As the supersaturated solution represent unstable condition, the excess dihydrate start to
precipitate in the form of nuclei of crystallization.
5. As the reaction continues, more dihydrate will be precipitated around the nuclei of crystallization
leading to crystal growth in spherulite shape
6.The reaction continues until all the
hemihydrate is transformed to dihydrate

 Manipulation :

1)powder should be stored tight seal to avoid humidity, some

companies provide preproportioned bags
2) water is added first then the powder to increase wetting &
decrease air bubbles & avoid dust formation
3) rubber bowel held in palm of the hand & mix for proper time by:
a) hand mixing:
▪ vigorous & wiping motion ( ‫) بقوة و ف اتجاه واحد‬
▪ it takes 1 minute to reach creamy mix
▪ then vibration of mix (either by tapping on table or by
vibrator)

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b) mechanical mixer with vacuum

▪ powder is incorporated during approximately 15 second of mixing with a hand spatula followed
by 20 to 30 seconds of mechanical mixing under vacuum
4) then pouring of impression either by boxing method (better) or inversion method

 Properties of Gypsum Products:

I. Setting Time:

 At final setting, the conversion of calcium sulfate hemihydrate to dihydrate is completed.

▪ Ready for use:
The time at which the set material may be safely handled in the usual manner. It may be considered
as the time when the compressive strength is 80% of that attained at one hour

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 Methods of measurement
1.Loss of gloss method:
▪ The set plaster when loses it surface
shine and smoothness.
▪ it is considered as the end of working time and
initial set has taken place.
▪ The material cannot be safely handled.
2. Exothermic reaction
• The temperature rise of the mass may also be used for measurement of setting time as the setting
reaction is exothermic
3.penetration tests:
a) Gilmore test:
- Initial setting time:
It is the time elapses from the beginning of mixing until the smaller Gilmore
needle of 1/4 pound weight and 1/12 inch in diameter does not penetrate the
surface.
- Final setting time:
It is the time elapses from the beginning of mixing until the heavier Gilmore
needle of 1 pound weight and 1/24 inch in diameter does not penetrate the
surface
b) Vicat needle test:
Initial setting time:
▪ It weighs 300 gm and the needle diameter is 1 mm.
▪ The time elapsing from the start of mixing till the needle does not penetrate
to the bottom of the plaster
 Control of Setting Time
▪ There are three factors that control setting time:
1. Solubility of the hemihydrate: Increasing solubility of the hemihydrate
achieves supersaturation of the dihydrate faster.
2. Number of nuclei of crystallization: The greater the number of nuclei of
crystallization, the faster the dihydrate crystals will form.
3. Rate of crystal growth: Increasing or decreasing the rate of crystal growth will
accelerate or retard the setting time.
▪ Factors controlled by the manufacturer:
1. Impurities ((Calcination)
a) If calcination is incomplete and excess gypsum (dihydrate) is left in the final product, the resulting
plaster will set faster.(as it will act as nuclie of crystallization)
b) If set gypsum (2%terra alba) is added
2. Particle size
• Finer the hemihydrate particle size, the faster the set, because:
a) Hemihydrate dissolves faster
b) The gypsum nuclei are more numerous and therefore, crystallization is faster.
3. Chemicals
o The most effective and practical method for the control of the setting time is the addition of certain
chemical modifiers to plaster or stone.
o If the chemical added decreases the setting time, it is known as an accelerator, if it increases the
setting time it is known as a retarder.
o Accelerators and retarders not only modify setting time, they also affect other properties like
setting expansion and strength

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Accelerators
▪ - Substances which decreases the setting time of
gypsum products by increasing the rate of
reaction.
1. Finely powdered gypsum (up to 19%) is
added by manufacturers to accelerate setting
time. Acts by providing additional nuclei of
crystallization
2. low concentrations salts like sodium or
potassium sulphate (2 to 3%) and sodium
chloride (up to 2%) are accelerators.
 They act by making the hemihydrate more
soluble.
 Sodium sulfate has its maximum acceleration
effect at approximately 3.4%.
Retarders
▪ generally, act by forming a layer on
the hemihydrate to reduce its solubility.
▪ It also inhibits the growth of gypsum crystals.
1. Borax (1-2%) is the most effective retarder.
During setting, it forms a coating of calcium
borate around the hemihydrate.
2. High concentrations, salts like sodium chloride
& sodium sulphate (3.4% to 20%) precipitate and
poisons the nuclei of crystallization.

▪ Factors controlled by the operator:

1. Water/Powder Ratio
▪ The more water used for mixing, the fewer nuclei of crystallization So, the setting time is
prolonged.
2. Mixing time and rate
▪ Increasing hand or mechanical mixing, breaks up some of the
formed dihydrate which increases the nuclei of crystallization. Thus
the setting time is decreased.
3. Temperature
▪ 20 -37 increase reaction rate & decrease setting time.
Why?
 Change in ion mobility with temperature.
 Change in the relative solubilities of calcium sulfate
hemihydrate (decrease with temperature) and calcium
sulfate dihydrate, which alters the rate of the reaction
 The net result is increase in reaction rate
▪ 37- 100 reaction rate decrease due to decrease in
solubility of calcium sulfate hemihydrate to be near calcium sulfate
dihydrate so supersaturation decrease
▪ As the temperature approaches 100’C: no setting takes as the
solubility of calcium sulfate hemihydrate equal calcium sulfate
dihydrate so no supersaturation
4. Humidity
o Humadity has double action
1. Small amount of dihydrate on the surface of the hemihydrate
powder additional nuclei of crystallization
shorten the setting time.
2.Increased contamination by moisture produces sufficient
dihydrate on the hemihydrate powder to retard the solubility of
hemihydrate causing lengthening of the setting time.
o For best results, all gypsum products should be kept in a closed container
5.Laboratory steps
• Clean instrument ...otherwise .... short setting
• Colloids such as gelatin, glue, agar, coagulated blood : retarders (nuclei poisoning)
• Avoid long contact ....surface soft ( as it retard reaction of gypsum

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