DENTURE BASE RESINS

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 ACRYLIC RESINS

The acrylic resins are derivatives of ethylene and contain

vinyl (-C=C-) group.

There are two acrylic resins series.

-Acrylic acid CH2=CHCOOH
-Methacrylic acid CH2=C( CH3) COOH
ADA specification No. 12

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 Requirements of resins

1. The liquid should be as clear as water & free of

extraneous matter and the powder should be free of dirt
or lint.
2. A satisfactory denture should result when the
manufacturer’s instructions are followed.
3. The denture base should be non-porous & free from
surface defects.
4. The cured plastic should take up high gloss & polish.
5. The processed denture should not be toxic to the oral
tissues.
6. The colour should be as specified.
7. The cured plastic should not show any bubbles or voids.
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 Types of denture base resins
Based on the mode of activation, they can be :
 Heat activated resin.

 Chemically activated, self cure or cold cure or auto

polymerized resins.

 Light activated resins.

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 HEAT – ACTIVATED DENTURE BASE
RESINS
 Thermal energy : Water bath
 Composition :

Powder Liquid
a)Poly methyl methacrylate and
other copolymers-5% a) Methyl methacrylate
b)Benzoyl peroxide – Initiator b) Hydroquinone - Inhibitor.
c) Dibutyl pthalate – plasticizer c) Glycol dimethacrylate - 1%
d) Compounds of mercuric to 2% by volume - a cross
sulphide, cadmium sulphide – linking agent
Pigments d) Dibutyl pthalate – plasticizer
e)Zinc or titanium oxide –
Opacifiers
f) Dyed organic filler and
inorganic particles like glass
fibres/beads - Esthetics
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 Polymerization Reaction
 By application of heat and pressure

Powder + Liquid +Heat Polymer +Heat

(Polymer + (Monomer) (External) (Reaction)
Initiator)

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 Compression molding technique

The technique can be described in the following steps :

1. Preparation of the mold
2. Selection and application of the separating media
3. Polymer – monomer ratio
4. Polymer – monomer interaction
5. Packing
6. Curing
7. Cooling
8. Deflasking, finishing and polishing

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1. Preparation of mold

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On completion of settting process, the record base & the
wax should be removed from the mold. To accomplish
this, the denture flask is immersed in the boiling water
for not more than 5 minutes.

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 2. Selection and application of separating
media
This medium must prevent direct contact between the denture base
resin & the mold surface.
Types of Separating Media:
 Tin foil
 Cellulose lacquers
 Solutions of alginate compounds
 Calcium oleate
 Soft soaps
 Sodium silicate
 Starches
The most popular separating agents are water soluble alginate
solution.

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Sodium alginate solution:
 2% sodium alginate in water, glycerin, alcohol, sodium
phosphate and preservatives.
 Reacts with the calcium of plaster to form a film of
insoluble calcium alginate.
Failure to place an appropriate separating media may cause 2
major difficulties:
1. If water is permitted to pass from the mold surface to
denture base resin, it may affect polymerization rate as well
as the optical & physical properties of the processed resin.
2. If dissolved polymer or free monomer is permitted to
soak into the mold surface, portions of the investing
medium may become fused to the denture base.

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 Precautions to be taken:
1. Waxes or oils remaining on the mould surface
will interfere with the reaction of the
separating medium and mould surface.
2. Continuity of the film will break if the mould
is steaming hot.
3. Coating of the medium left on the teeth will
prevent bonding of teeth with the denture
base

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3. Polymer to monomer ratio
 The polymerization of denture base resin results in
volumetric and linear shrinkage.
 The accepted polymer to monomer ratio is 3:1 by volume
or 2:1 by weight.
 This provides sufficient monomer to thoroughly wet the
polymer particles but does not contribute excess monomer
that would lead to increased polymerization shrinkage.
 Using 3:1 ratio the volumetric shrinkage may be limited to
approximately 6% (0.5% linear shrinkage.)

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 Too much monomer Too little monomer

1. Greater curing or 1. Not all polymer beads

polymerization will be wetted by the
shrinkage. monomer and the cured
2. More time to reach the acrylic will be granular.
packing consistency. 2. Dough will be difficult
3. Porosity in the denture. to manage and it may
not fuse into a
continuous unit of
plastic during prossing.

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 4. Polymer – monomer interaction
When polymer and monomer are mixed
in proper proportions, a workable mass is
produced.
On standing, it passes through 5 distinct
stages :
i. Wet Sand stage: no interaction at
molecular level. Consistency of mixture—
coarse or grainy.
ii. Stringy/Sticky stage: Some polymer
chains are dispersed in liquid monomer.
Stage is characterized by stringiness or
stickiness when material is touched or
drawn apart. Monomer attacks the
polymer.
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iii. Dough stage: An increased number of polymer chains enter
solution. A sea of monomer & dissolved polymer is formed.
The physical & chemical characteristics exhibited during the
later phases of this stage are ideal for compression molding.

v. Rubbery or elastic stage: Monomer is dissipated by

evaporation & by further penetration into remaining polymer
beads. Mass rebounds when compressed or stretched.

v. Stiff stage: This may be attributed to evaporation of the free

monomer. Clinically, the mixture appears very dry & is
resistant to mechanical deformation.

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 Dough forming time
The time required for the resin mixture to reach a
doughlike stage is termed the dough forming time.
Clinically, most resins reach dough like stage in less than
10 min.

 Working time
It is defined as the time that a denture base material
remains in the dough like stage. ADA specification no. 12
requires the dough to remain moldable for atleast 5 min.
The working time of the resin may be extended by
refrigeration.
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5. Packing
 The placement and adaptation of denture base resin
within the mold cavity is termed as packing.
 Over packing:
- Placement of too much material.
- Leads to a denture base that exhibits excessive
thickness and resultant malpositioning of prosthetic
teeth.
 Under packing:
- Use of too little material
- Leads to noticeable denture base porosity.

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 Steps in resin packing:

A. Resin is rolled into a rope like form and is bent into a horseshoe
shape and placed into the mold cavity.

Packing too early :

- Material – too low viscosity
- Flow out of the flask too easily
- Porosity of the denture base.

Packing too late :

- Material - too viscous
- Movement or fracture of the teeth
- Loss of details
- Increased vertical height of the denture

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B. Trial closure :
- Polyethylene sheet is placed over
the resin and the flask is
reassembled.
- The flask assembly is placed into
the specially designed press and
pressure is applied incrementally.

Excess resin will be found on the

relatively flat areas surrounding
the mold cavity. This excess resin is
called flash. Flash is carefully
teased away from the body of the
resin.
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 When flash is no longer apparent,
definitive closure of the mold
may be accomplished. The flask
is then transferred to a flask
carrier that maintains pressure
on the assembly during processing.

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6. Curing
 Bench curing :
After final closure, the flasks are kept at room
temperature for 30 to 60 minutes.
Purpose :
- Permits an equalization of pressure throughout the
mold.
- Allows time for uniform dispersion of monomer
throughout the mass of dough.
- Longer exposure of resin teeth to the monomer
produces better bond of the teeth with the base
material.

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 Polymerization cycle :
The heating process used to control the polymerization is termed as
the polymerization cycle or curing cycle.

A. Long cycle:- 74℃ for 8 hours.

B. Short cycle:- 74℃ for 2 hours then increasing the temperature to
100℃ for 1 hour.

7. Cooling

 Rapid cooling - Warping of the denture base because of differences

in thermal contraction of resin and investing stone.
 Bench cooling – 30 minutes.
 Immersed in cool tap water – 15 minutes.

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8. Deflasking, finishing and polishing

 Retrieving cured acrylic denture from the flask-

Deflasking
 Care – to avoid flexing and breaking of the acrylic
denture.
 Denture is trimmed and smoothened using sandpaper.
 Finely ground pumice in water is used for final
polishing.

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 Injection molding technique
 Resin –
Special thermoplastic resin

 Flask –
Specially designed flask

 Master cast is placed in one

half of the flask and invested
with dental stone.

 Sprues are attached to the

denture base.

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 The remaining portion of the
flask is positioned and the
investment process is
completed.

 Wax elimination is performed.

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 The flask is then reassembled and placed into a carrier.
 Resin is mixed and injected into the mold cavity at room
temperature.
 Flask is then placed into the water bath.
 As the material polymerizes, additional resin is introduced
into the mold cavity.
 Upon completion, the denture is recovered, adjusted,
finished and polished.

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 Advantages :
1. No trial closures are required.
2. Dimensional accuracy
3. Low free monomer content.
4. Good impact strength.

 Disadvantages :
1. High cost of equipment.
2. Difficult mould design problems.
3. Less craze resistance problems

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Polymerization via microwave energy
 Resin :
Specially formulated resin
 Flask :
Non metallic flask
 Thermal energy source :
Conventional microwave oven

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 Advantages :
1. It is cleaner and faster than the conventional hot
water.
2. The physical properties of the microwave resins
and the fit of the denture bases are comparable to
conventional resins.

 Disadvantages :
1. Flasks are relatively expensive & have tendency
to break down after processing several dentures.
2. Packing pressure cannot exceed 1200 psi.

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 CHEMICALLY ACTIVATED DENTURE BASE
RESINS
COMPOSITION :
Powder Liquid
1. Poly methyl methacrylate and other
copolymers – 5% 1.Methyl methacrylate monomer
2. Initiator - Benzoyl peroxide 2.Activator - Dimethyl – p –
3. Dyes - Compounds of toluidine
3.Plasticizer - Dibutyl phthalate
mercuric sulphide,
4.Cross linking agent - Glycol
cadmium sulphide dimethacrylate
4. Opacifiers - Zinc or titanium 5.Inhibitor - Hydroquinone -
oxide 0.006%
5. Plasticizer - Dibutyl phthalate

6. Dyed organic fillers

7. Inorganic particles like glass fibers or
beads
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Setting Reaction:-
 In most cases chemical activation is accomplished
through the addition of a tertiary amine such as dimethyl –
para toludine.
 Upon mixing the tertiary amine cause decomposition
of benzoyl peroxide – consequently free radicals are
produced and polymerization is initiated.
 As a general rule, the degree of polymerization
achieved using chemically activated resins is not as
complete as that achieved using heat-activated resins – this
indicates there is a greater amount of unreacted monomer.
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 Comparison of self cure and heat cure acrylic
resins
Self – cure acrylic resin Heat cure acrylic resin

Higher residual monomer content – Lower residual monomer content –

3%-5% 0.2% - 0.5%
Less shrinkage More shrinkage

Poor colour stability Colour stability is good

Porosity is greater Porosity is less

Lesser strength, greater creep, Superior strength, low creep, lesser

greater distortion, higher initial distortion, less initial deformation
deformation
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 Manipulation
 Sprinkle on technique
 Adapting technique
 Fluid resin technique
 Compression mold technique
 Injection mold technique

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Sprinkle on technique
 Separating media is applied.
 Powder is sprinkled on the cast and wet with monomer.
 Prosthesis is constructed section by section until
completion.
 Prosthesis is further cured in hot water under pressure for
20 minutes using a pressure pot.

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Adapting technique :
 Powder and liquid are proportioned and mixed in a
glass or porcelain jar.
 When it reaches the dough stage, it is quickly removed
and adapted onto the cast and it is manually moulded
quickly to the desired shape.
 Alternative technique using a template :
-The resin is preshaped using a roller and template
before adapting it to the cast.
 Curing is completed in a pressure pot.

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Fluid resin technique

 Resin used:
Pourable, chemically activated resin
 Polymer:Monomer ratio :
Lower – 2:1 to 2.5:1

A. Completed tooth arrangement

is positioned in the fluid resin flask.
The flask is filled with reversible
hydrocolloid investing medium and
the assembly is cooled.

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B. The cast with the attached tooth
arrangement is removed from
the flask.

C. The sprues and vents are cut

from the external surface of the
flask to the mold cavity.

Wax is eliminated from the cast

using hot water.

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D. The prosthetic teeth are
retrieved and carefully seated
in their respective positions
within the hydrocolloid
investing medium.
Subsequently, the cast is
returned to its position within
the mold.

E. The resin is mixed according to

manufacturer’s directions and
poured into the mold cavity
via sprue openings.

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 - The flask is then placed in a pressurized chamber at room
temperature and the resin is permitted to polymerize.
- Only 30 to 40 min is required for polymerization.
Nevertheless, a longer period is suggested.

F. Following the polymerization,

the denture is retrieved from
the flask & sprues are removed.

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Advantages
 Improved adaptation to underlying soft tissues.
 Decreased probability of damage to prosthetic teeth &
denture base during deflasking.
 Simplification of flasking, deflasking & finishing
procedures.
Disadvantages
 Noticeable shifting of prosthetic teeth during processing.
 Air entrapment within the denture base material.
 Poor bonding between the denture base material &
acrylic resin teeth.
 Technique sensitivity.
 Physical properties are somewhat inferior to those of
conventional heat processed resins.
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LIGHT-ACTIVATED DENTURE BASE RESINS

Composition
 Matrix - Urethane dimethacrylate, microfine
silica,
high molecular weight acrylic resin
monomer
 Organic filler - Acrylic resin beads
 Initiator - Camphorquinone
 Activator - Visible light
Dispensing
 Single component - sheet & rope
forms packed in light proof pouches
to prevent inadvertent polymerization. 42
Fabrication
 The denture base material is
adapted to the cast while it is in
plastic state. The denture base
can be polymerized without
teeth and used as base plate.
 The teeth are added to the base
with additional material &
anatomy is sculptured while
the material is still soft.
 It is polymerized in a light
chamber with blue light of 400-
500nm from high intensity
quartz – halogen bulb.

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 Properties of denture base acrylics

Methyl Methacrylate :
• Molecular weight :100

• Melting point : -480C

• Boiling point :100.80C.

• Density : 0.945 g/ml at 200C

• A volume shrinkage of 21% occurs during the

polymerization of the pure methylmethacrylate

monomer.

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Poly methyl methacrylate:
 Transparent resin of remarkable clarity.
 Density – 1.19 g / cm3.
 Tensile strength – 60 Mpa
 Knoop hardness number -18 to 20.
 Modulus of elasticity – 2.4 Gpa.
 Chemically stable to heat
 Softens at 1250C
 Between 1250C and 2000C depolymerization takes place
 At approximately 4500C, 90% of the polymer

depolymerizes to form the monomer.

 Tendency to absorb water.
 Soluble in organic solvents such as chloroform and acetone.

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1. Strength:-
A. Tensile & compressive strength :
Compressive strength:- 75 MPa
Tensile strength:- 52 Mpa

Strength is affected by :

• Composition of the resin

• Technique of processing
• Degree of polymerization
• Water sorption
• Conditions presented by the oral environment

Chemically activated resins : Decreased strength and stiffness

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 Fractures :
- Accidental dropping of denture
- Faulty fabrication

B. Impact Strength:-
It is a measure of energy absorbed by a material
when it is broken by sudden blow
Addition of plasticizers and fillers increases the
impact strength.
Self cured resins have lower impact strength.

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C. Hardness:- acrylic resins have low hardness so
they can be easily scratched and abraded.
Heat cure :- 18-20 KHN
Self cure:- 16-18 KHN

D. Modulous of elasticity:- 2400 Mpa.

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2. Dimensional stability:-
A. Shrinkage:- 2 reasons
1. Thermal Shrinkage on cooling
2. Polymerization shrinkage

 Volume shrinkage:- 8%
 Linear shrinkage:- 0.53%

B. Water sorption:- acrylic resins absorb water

(0.6mg/cm2) and expand.
Solubility – resins are insoluble in water and oral
fluids.
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3. Thermal properties:-

A. Stability to heat:-
 softens at 125℃
 Depolymerizes between 125℃- 200℃
 At 450℃, 90% of polymer is converted to monomer

B. Thermal conductivity:- poor conductors of heat and

electricity.

C. Coefficient of thermal expansion:- high – 81x10-6/℃

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4. Color stability:- heat cure > self cure.
5. Biocompatibility :- completely polymerized acrylic
resins are biocompatible.
Monomer – skin allergies, toxic if inhaled over long
time.
Residual monomer- can be reduced by heat curing for
longer time.
6. Adhesion:- to metal and porcelain is poor – so give
mechanical retention.
7. Shelf life:- powder/liquid form- good shelf life
gel form- low shelf life.
8. Taste and odor:- completely polymerized acrylic
resins are tasteless and odorless.
9. Esthetics :- pigments can be incorporated.
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 POROSITY
 It is a processing error in acrylic resins.
 Types :- Internal and External porosity

1. Internal porosity:-
 It is in the form of voids or bubbles within the

mass of polymerized acrylic.

 It is confined to the thick portions of the denture

base and may not appear equally throughout the

affected area.
Causes:- vaporization of monomer when the
temperature of the resin increases above the
boiling point of the monomer(100.8℃).
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2. External porosity:- occur due to 2 reasons
a. Lack of homogeneity: if the dough is not
homogenous at the time of polymerization, the
portions containing more monomer will shrink
more than the adjacent area. This localized
shrinkage results in voids and resin appears white.
This can be avoided by taking proper powder liquid
ratio, mixing it well and packing at dough stage
only.
b. Lack of adequate pressure / insufficient material:
bubbles appear which are not spherical and the
resin appears white.

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 CRAZING
 Formation of the surface cracks on the denture base resin.
 Transparent resin - Hazy or foggy appearance than cracks.
Tinted resin – Whitish appearance.
 Crazing has weakening effect on the resin & reduces the
esthetic qualities. The cracks formed can cause fracture.
Causes of crazing
1. Mechanical stresses: mechanical separation of
individual polymer chains on application of
tensile stresses.
Crazing generally begins at the surface of the
resin & is oriented at right angles to tensile forces.
2. Solvent action : More randomly oriented.
3. Incorporation of water

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 DENTURE CLEANSERS
 Agents used : Method :
 Dentifrices  Immersion in the agent
 Denture cleansers  Brushing with the cleanser
 Mild detergents
 Commercial denture cleansers :
 Powder/Tablet
 Composed of alkaline compounds, detergents,
flavoring agents and sodium perborate

When the powder is dissolved in water, the perborate

decomposes to form an alkaline peroxide solution,
which in turn decomposes to liberate oxygen. The
oxygen bubbles then act mechanically to loosen the
debris.
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 Infection control procedures
 Prevention of cross-contamination between patients and
dental personnel.
 Prostheses : Ethylene oxide gas
 Rag wheels : Autoclave

Care of acrylic dentures:

1. Patient should be cautioned to keep the denture moist
when they are not wearing them, since dimensional
changes can occur due to drying.
2. Patient should be instructed not to use abrassive
dentifrices .
3. Dentures should not be cleaned with hot water, since
processing stresses can be released and can result in
permanent deformation and distortion.
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 Resin teeth
 More than 60% of artificial teeth are made of
acrylic and vinyl acrylic teeth.
 Most resin teeth are based on poly methyl
methacrylate chemistries, similar to that used in
denture base resins.
 Chemical bonding to prosthetic teeth and heat
activated denture base resins is extremely
effective.
 Bonding between prosthetic teeth and chemically
activated resins is through mechanical retention.

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 Missellaneous resins and techniques

 Fractures of denture may be repaired using

compatible resins.
 Repair resins may be
-Conventional heat polymerized
-Microwave polymerized
-Chemically activated
Chemically activated resins are generally
preferred as they may be polymerized at
room temperature.

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 SOFT LINERS
 The purpose of the soft liner is to absorb some of the energy,
produced by the masticatory impact, that would otherwise be
transmitted through the denture to the soft basal tissue.
 Types :
1. Plastisized acrylic resins :
Composition:
Powder : Polyethyl methacrylate or higher methacrylates like
ethyl N-butyl-N-propyl and copolymers
Liquid : Acrylic monomer and plasticizer

- Leaching of plasticizer - Rigid

Less plasticizer is required and effect of leaching can be

minimized. 59
2. Vinyl resins : Poly(vinyl chloride) and Poly(vinyl
acetate) – subject to leaching and harden during use.
3. Silicone rubbers : Most successful material
 Retain their elastic properties for a prolonged periods
but may loose adhesion to underlying denture base.
 Chemically activated silicones – two component
system
-polymerize via condensation reaction.
 Heat activated silicones – One component system –
Paste/Gel

4. Other polymers : a. Polyurethane

b. Polyphosphazine rubber.
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 Tissue conditioners
Certain conditions of health debilitation or ill-
fitting dentures, can cause oral tissue to
become inflamed and distorted.
Relining the denture with a tissue conditioner
allows the tissues to return to ‘normal’, at
which time a new denture can be made.
Composition : highly plasticized acrylic resins,
supplied as powder and liquid.
Powder Liquid
Poly(ethyl methacrylate) or one of Aromatic esters(butyl phthalate
its copolymers. butyl glycolate) in ethanol or an
alcohol of high molecular weight.

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 Special tray acrylic resins
 Specialized chemically
activated resins
 Powder and liquid form
 High amount of inorganic
fillers (Eg. French chalk) –
Increases plasticity and
workability
 Green / Blue

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