FABRICATION OF THE
3-UNIT METAL-CERMAIC
FIXED PARTIAL DENTURE
Andrea D. Jackson, DDS, MS, FACP
Howard University College of Dentistry
GOAL:
Expose the student to the laboratory fabrication of a posterior three-unit
metal – ceramic fixed partial denture. The student will also be exposed to the
soldering procedure for gold and ceramo - metal alloys and the uses of solder.
OBJECTIVES:
The student upon completion of the instruction session and suggested
reading assignments should be able to:
A. Understand the requirements for the wax pattern of a three-unit metal – ceramic fixed partial
denture.
B. Understand the concept of cut-back for porcelain application in the wax pattern
C. Understand the various pontic designs.
D. Understand the indirect spruing procedure and the reason for it.
E. Understand and select the proper investment for metal – ceramic alloys and
the investing procedures
F. Understand the burnout, casting, and divesting procedure and how it differs from gold alloys.
H. Understand the finishing procedure and the preparation of the surface for porcelain application.
I. Understand the reasons for uses of solder
J. Understand the process involved in soldering
K. Understand the difference between pre and post solder
L. Understand the classification and requirements of a solder
Clinical Considerations
Clinical execution of Clinical procedures necessary
tooth preparation for proper laboratory
fabrication
Finish-line design
Impression making
Proper axial reduction
Placement of retraction cord
Proper occlusal/proximal Capturing details of
reduction preparation
Reduction appropriate for Inter-occlusal registration
selected restorative
Articulation of cast
materials
TERMS/DEFINITIONS
Framework – Fixed Coping – single tooth
partial denture or metal thimble
occlusal single unit
Sequence of Procedures and Clinical
Considerations:
Tooth
Preparation/Design
Combination
Shoulder
Chamfer
Location
Proper Taper
Adequate tooth reduction
parallelism
Metal-ceramic restoration design
Metal-Ceramic
Restoration
Ceramic layer
Metal understructure
Framework
Copings
Esthetics
LABORATORY PROCEDURES
Waxing
Wax add-on technique
Full-cast crown
PFM crown
Pontic
Full anatomic wax-up
Specifications for FPD
Tooth #19 – full cast metal retainer
Tooth #20 – PFM pontic
Tooth #21 - PFM
LABORATORY PROCEDURES
Wax cutback of pontic and retainer unit
Well-rounded
No undercuts
No concavities
No sharp corners
No angles
Finished Wax Patterns
No inner surface defects
Smooth, polished outer surfaces
COPING/FRAMEWORK DESIGN
There are four features of importance to be
considered when designing the metal coping for a
metal-ceramic restoration:
1.Thickness of metal underlying and adjoining the
porcelain
2.Placement of occlusal and proximal contacts
3.Extensions of the area to be veneered for
porcelain
4.Design of the facial margin
LABORATORY PROCEDURES
Coping design
Thin porcelain of uniform thickness
Rigid metal
Convex surfaces
Noble vs. base metals
Dental porcelains (which are, chemically
speaking, glasses) resist compressive
loading but tend to succumb to tensile
stress.
Therefore, the metal substructure must
be designed so that any tensile stresses
in the porcelain are minimized.
Ideally, an esthetic restoration should wear at approximately the same
rate as the enamel it replaces (about 10 µm per year5.) In addition, the
restoration should not increase the wear rate of an opposing enamel
surface.
Dental porcelain is more abrasive of enamel than of other restorative
materials (e.g., gold or amalgam, and has been implicated in severe
occlusal wear, particularly when the porcelain is not glazed or highly
polished.
This factor should be considered whenever a metal-ceramic restoration
is being designed.
Restorations with porcelain occlusal surfaces
must be planned carefully. Although they are
esthetically very acceptable, these restorations
have disadvantages, especially wear of the
opposing enamel.
Types of Facial Margins
1. Metal margins
1. – unesthetic
2. Porcelain margins on
metal collar
1. – over contoured
3. All porcelain margins
1. – most esthetic
To avoid fracture, the thickness of a ceramic veneer must not exceed 2
mm; however, a To avoid fracture, the thickness of a ceramic veneer
must not exceed 2 mm; however, a minimum thickness of 1 mm is
needed for an esthetically pleasing restoration.
Coping Design - Thickness of
Metal
Thin uniform thickness of porcelain supported by
rigid metal is strongest
Absolute minimum thickness of porcelain is .7mm
Desirable thickness for porcelain is 1mm
Minimum thickness with good esthetics
Always compensate with extra thickness of metal
when the tooth preparation allows for more
clearance
Maximum restoration strength and longevity is
achieved by coping rigidity
Coping design continued
Surface should be convex Proximal contacts on anterior
Occlusal contact must be teeth should be in porcelain
1mm from porcelain-metal for esthetic reasons
junction Porcelain opposing natural
Minimum thickness is .3 -.5 teeth can cause wear of the
mm for noble metals opposing teeth-must make
patient aware that a
Higher yield strength base restoration may be needed in
metals copings can be as thin the future
as .2mm
The ultimate goal of 1mm of
uniform porcelain thickness
will determine thickness of
coping
Full contour wax- up and cut-back
The correct steps in the fabrication of a metal- If the coping pattern (A) is the first step in
ceramic restoration: A, full-contour wax pattern; fabrication, the porcelain veneer on the final
B, coping wax pattern cut back; C, porcelain restoration may have contours that are not
addition to metal coping. continuous with those of the unveneered coping
(B).
Full contour > > > Cut - Back
METAL – PORCELAIN DESIGN
CUT BACK >>>COPING DESIGN
Alloys
Classification for Dental Casting Alloys
Noble metal content: Au, Pt, Pd
(minimum percentage by weight)
High-noble metal
60% (>40% gold)
Noble metal
25% (no gold requirement)
Predominantly base metal
<25% (no gold requirement)
Au, gold; Pd, palladium; Pt, platinum.
Alloys Used for Fabricating
Metal-Ceramic Restorations
High noble
Gold-platinum-palladium
Gold-palladium-silver
Gold-palladium
Noble
Palladium-silver
High palladium
Predominantly base
Nickel-chromium
Nickel-chromium-beryllium
Cobalt-chromium
Dental Casting Alloys
Classifications
High-Noble metal content
Noble-noble metal content of 60% or greater. At least 40% of the alloy must be
gold.
Noble metals
must be at least 25% noble metal.
Predominately Base
a noble metal content of less than 25%.
Cost
Precious
Semi-precious
nonprecious
Titanium Alloys
Titanium based alloys have been studied
since the late 1970’s as potential casting
alloys.
Advantages of titanium:
Excellent bio-compatibility and corrosion
resistance
Titanium oxide surface
Low density in comparison to gold or palladium
resulting in lighter and possibly less expensive
restorations
Titanium Disadvantages
The dental casting of titanium and titanium
alloys poses special problems because of the
high melting point of titanium (1668° C)
Its strong tendency to oxidize and react with
other materials.
Special casting machines needed that provide either a
vacuum environment or an argon atmosphere
must be used.
Dental Casting Alloys
Predominantly base alloys
Noble metal < 25%
Challenge to dentists and technicians
Physical properties
Handling characteristics
Fabrication techniques
Higher fusing elements
higher melting temperature 2300-2600 degrees
Fahrenheit
Necessitates use of gas-oxygen torch and phosphate-
bonded investment with high-heat burnout
Titanium disadvantages
Selecting a dental laboratory experienced in
fabricating these castings is essential, and such
dental laboratories are not common in the United
States. Further research is needed to optimize the
metallurgical structure and casting technology for
titanium alloys,
Base Metal Alloys
The potential health problems associated with
beryllium- and nickel-containing alloys have
led to the development of another alternative
base metal alloy system: cobalt-chromium.
The representative Co-Cr alloys have higher
hardness than the Ni-Cr alloys suggests that
finishing restorations made with the former
alloys may be more difficult.
Clinical
Case
LABORATORY INSTRUMENTS FOR
FABRICATION OF CAST RESTORATIONS
CONSTRUCTION OF
WORKING CASTS and
die
CONSTRUCTION OF A
WAX PATTERN
LABORATORY INSTRUMENTS FOR
FABRICATION OF CAST RESTORATIONS
CONSTRUCTION OF
WORKING CASTS
CONSTRUCTION OF A
WAX PATTERN
LABORATORY PROCEDURES
Pontic Design
Modified ridge lap pontic
Other pontic designs
Saddle
Hygienic
Ovate
PONTIC DESIGN
Size and shape of connectors
Posterior Anterior compared to posterior
METAL – CERAMIC RELATIONSHIP
The melting range of the alloy used in the coping must be 170 to
280°C (300 to 500°F) higher than the fusing temperature of the
porcelain applied to it.
The metal coping is an important part of the metal-ceramic
restoration, and one that unfortunately is often overlooked. Its
design can have an important effect on the success or failure of the
restoration.
LABORATORY PROCEDURES
Spruing Patterns for metal-ceramic fixed
partial dentures must be sprued
Indirect (Runner Bar by an indirect method because
the alloys used fuse and solidify at
Technique) much higher temperatures.
Feeder sprues Because the ambient air is much
Transverse bar colder than the molten metal, the
exposed button is likely to solidify
Manifold sprues while the metal at the center of
the ring is still liquid.
Direct
This means that the button
Main sprues cannot serve as a reservoir to
prevent shrink-spot porosity.
6 mm from wax pattern to Instead, a bulky horizontal runner
end of ring bar is placed between crucible
6 mm from top of crucible former and pattern.
former
runner bar – stabilizes pattern; serves as reservoir for solidification and contraction,
equalizes flow of metal through all parts of mold,
Pattern for a metal-ceramic fixed
partial denture is sprued indirectly. Molten alloy swirls through the manifold system,
The feeder sprues and the horizontal raising the temperature of the surrounding invest-
runner are 8 gauge, and the ment (shaded area).
manifold sprues are 10 gauge.
LABORATORY PROCEDURES
INVESTING
Solidification shrinkage of metal:
Surrounding wax pattern with multi-metal shrinks as cooling
material that duplicates its occurs
shape and anatomic features Smaller casting as a result
Requirements Expansion of Mold (> original
Reproduce precisely pattern)
Sufficient strength to withstand 4 mechanisms
burn-out/casting 1.Setting expansion (silica particles
interfere with forming crystalline
Expand to counter solidification structure of gypsum-bonding)
shrinkage
2.Hygroscopic expansion (hydration
process)
3.Wax pattern expansion
4.Thermal expansion of the
investment
LABORATORY PROCEDURES
It may be necessary to paint phosphate-bonded
investment into the wax pattern with a small brush.
Investing
De-bubblizer
Reducing surface tension
Liner
Cellulose ***
Unrestricted thermal expansion
Ceramic
Mixture
60 grams powder : 9.5 cc liquid
Mix under vacuum (vac-u-spat)
Bench set for one hour after
investing
Scrape top of casting ring after
setting
Allow gases to escape during
burn-out
LABORATORY PROCEDURES
Phosphate bonded Gypsum bonded
investment investment
Higher fusing alloys fuse <1975 degrees
Stronger & withstands Fahrenheit
higher temperatures Gold alloys
Used for investing casting Type I: small inlays
alloys with higher Type II: larger inlays and
temperatures onlays
Silver palladium Type III: onlays, crowns,
Gold platinum short-span FPD
Type IV: long-span FPD;
thin veneer crown; RPD
LABORATORY INSTRUMENTS FOR
FABRICATION OF CAST RESTORATIONS
CONSTRUCTION OF
WORKING CASTS
CONSTRUCTION OF A
WAX PATTERN
INVESTING AND
CASTING
INVESTED WAX PATTERN
LABORATORY PROCEDURES
BURNOUT
Removal of wax pattern to create mold into which molten alloy is placed
Thermal expansion of the mold
Investment allowed to harden,
Scrape top to allow gasses to escape
Place in oven at 600 degrees F for 30 minutes
Then to 1300 degrees Fahrenheit for1 hour
If longer, investment may start to break down
Investment and ring expand to compensate for shrinkage
LABORATORY PROCEDURES
Casting
-Crucibles
-Gas-Oxygen systems
-Induction casting machine
-Electric melting machines
As the alloy begins to solidify, the heat around the
manifold (dark shading) keeps it molten longer,
preventing porosity in the bridge.
)>
Gas-air torches for lower temperatures
LABORATORY PROCEDURES
Finishing
Divesting Remove sprue and button
from casting
Bench cool for 1 hour
Use stones, sandpaper, and
Break investment with
burs to finish
pointed instrument
Aluminum oxide abrasive
to clean casting
Ultrasonic cleaning
Sprue immediately adjacent to the
casting is removed with a separating
disc.
LABORATORY PROCEDURES
Polishing
Silicone wheels and cones
Abrasive paste or
compound
Common shapes of abrasive stones are:
cone (CN), flame (FL), cylinder (CY),
barrel (BA), wheel (WH), inverted cone
(IC), knife edge (KN), round (RD), round
edge (RE).
CASTING DEFECTS
LABORATORY INSTRUMENTS FOR
FABRICATION OF CAST RESTORATIONS
CONSTRUCTION OF
WORKING CASTS
CONSTRUCTION OF A
WAX PATTERN
INVESTING AND
CASTING
PREPARATION FOR PORCELAIN
APPLICATION – preparing the metal
Do not use any polishing compounds,
The coping thickness is checked as they may contaminate the surface
with an Iwanson thickness gauge. of the metal to be veneered later.
The veneering area is
prepared with aluminum
oxide stones.
PREPARING THE METAL
The final step in metal preparation is reduction
of the oxide layer on the part of the coping to be Must be cleaned and
veneered with porcelain by air abrading with . uncontaminated from
50 μm aluminum oxide.
oils from the skin or
debris from finishing
with steam
Metal framework finishing
LABORATORY INSTRUMENTS FOR
FABRICATION OF CAST RESTORATIONS
CONSTRUCTION OF
WORKING CASTS
CONSTRUCTION OF A
WAX PATTERN
INVESTING AND
CASTING
PORCELAIN
APPLICATION
Heat Treatment – Oxidation
cycle
Coping is placed in furnace and the
temperature raised from 300 – 400 oC
Directions are alloy specific
Removal of hydrogen gases that was incorporated
in the casting process
Porcelain buildup - Opaque
application
Done to mask the metal, supply the base shade, and
creates the initial bond
The veneering surface of the coping Two layers of opaque are baked
is wetted with distilled water or special individually
liquid recommended by the manufacturer.
Application of Dentin porcelain/
Body porcelain
Made with a brush
Tissue is used to absorb water
Over build contour to compensate for shrinkage
A sable brush is used for condensing and final shaping
Cut back and apply Incisal/
enamel porcelain
Create translucency and esthetics
Done with a spatula on the inciisal edges and proximal contact areas
cutback
Cut back and apply Incisal/
enamel porcelain
Incisal porcelain ready for Adding small amount to proximal
firing Contact before firing
Firing / Baking porcelain
Requires more than one bake to make
adjustments in the contours
A clean green stone is used for contouring
Finishing Porcelain
Shade modification done prior to final finish if necessary
Auto glaze – glazes itself during firing process
Must avoid over firing
Applied glaze - a low fusing clear porcelain is applied and baked
to the surface
Polishing – done on small areas that may have been adjusted in
the mouth
May be less destructive to opposing tooth structure
*Finishing the metal is the same as any other metal
LABORATORY INSTRUMENTS FOR
FABRICATION OF CAST RESTORATIONS
CONSTRUCTION OF
WORKING CASTS
CONSTRUCTION OF A
WAX PATTERN
INVESTING AND
CASTING
PORCELAIN
APPLICATION
Bisque bake try-in
Cementation of definitive
restoration
JOINING METALS/ SOLDERING
The addition of filler Soldering
Uses: Classification
Soldering/joining units of Fineness (gold content)
conventional gold alloy Characteristics
(FPD’s, splints) Corrosion resistant
Adding proximal contacts Lower fusing
Repairing casting voids Non-pitting
Soldering porcelain fused Strength
to metal alloys
Free-flowing
Welding (melting)
Pre and Post Soldering for metal
ceramic restorations
Pre-Soldering Post – soldering
Done prior to placing the Done after the porcelain is
porcelain placed
Wax patterns for metal-ceramic fixed partial dentures are
invested and cast as one unit whenever possible because of the
difficulty encountered in soldering the alloys used for this type of
restoration
Gold Solder Fineness
Refers to parts per thousand of the solder that is
gold
Ex:
600 fine solder is 600 parts of gold per 1,000 or
60% gold. (minimum that should be used is 580 fine)
The higher the fineness, the higher the melting range and the
more corrosion resistance
A casting alloy is designated by carat (refers to parts per 24
ex: 18K = 75% gold
A solder designated 18K means it should be used with 18K
casting alloy
Soldering
Solder should possess a fusion temperature
that is about 60 degrees C (100 – 150 F) below
that of the metal being soldered
Four- and five-unit fixed partial dentures
joined by soldering have better-fitting
margins than do one-piece castings of the
same length.
Any fixed partial denture larger than three
units should still be cast in two pieces and
soldered.
The SOLDERING procedure
An index is made in the mouth, the restoration is invested and soldered.
1. Applying anti-flux 2. Heating the area to be joined
3. Adding solder 4. Completed solder joint
