Lec. 14 D. M.

Dental Materials Assis. Prof. Dr.
Ibrahim Alfahdawi
Lec. 14
Molding Technique
1- Compression technique.
2- Injective technique.
Compressive technique includes: Preparation of the mold, the stone cast

with the record denture base, wax and teeth embedded in investing media
(plaster) in the lower half of a flask after setting of the plaster a layer of
separating medium is applied on the top of this layer. Another mix of plaster
is applied over the first layer until the flask is completely filled with the
plaster, we wait until the plaster is completely set (hard) then the flask is
heated to soften or melt the wax. Then the two halves of the flask is separated,
the wax is removed, the cast is cleaned or washed from any remnants of wax
then separating medium is applied on the cast surface and on the mold surface
for two reasons:
1. To prevent the monomer and dissolved polymer from entering into the cast
surface because there will be bond between the cast and acrylic, so the result
is impossible cleaning of the inner side of the denture.
2. To prevent the water from the mold to enter into the acrylic which will
affect the polymerization rate and the color of the finished denture.
Mixing and placing of the acrylic: The powder is mixed with the liquid
according to the manufacture instruction 3:1 by volume or 2-2.5:1 by weight
(if P/L ratio is too high not all polymer will be granular, also if this ratio too
low there will be great shrinkage). This mixing is done in clean glass jar,
which should be covered to prevent evaporation of the monomer.
Packing: Is done in the dough stage, the dough is rolled into rope like form
and placed in the upper half of the flask then the polyethylene (nylon) sheet
or cellophane sheet is placed over the dough in the upper half of the flask.
Then the lower half is pressed on the upper half slowly to spread the dough
evenly through the mold then the two halves are separated, the excess material
(called flask ) is removed by wax knife at least two trial closure is done.
1
Dental Materials Assis. Prof. Dr. Ibrahim Alfahdawi
Before the final closure a thin layer of separating medium is applied in the
cast, the polyethylene sheet is removed, and then two halves of the flask is
closed under pressure by a bench press for about 100kg /cm2. A small excess
is packed to compensate for polymerization shrinkage (but if too excess is
packed, the denture base will be very thick and cause increasing in the vertical
dimension. The packing should not be done in sticky stage because it will lead
to porosity also should not be done in rubbery stage because great force is
needed to flow the material and to close the flask which may cause increasing
in the vertical dimension by forcing the teeth inside the mold.
Curing: Means polymerization to produce the final denture; pressure is

applied during curing for:
1. To decrease the effect of thermal expansion.
2. Lead to the reduction of polymerization shrinkage.
3. To decrease the evaporation of monomer, thus decrease porosity.
Generally, we have two curing cycles:-
First, slow heat cycle:
70°C for 7hr then 100°C for 3hr, or
75°C for 6hr then 100°C for 1hr
Recently 74°C for 1½hr (Philips 1996) and 100 °C for ½hr
Second short heat cycle (rapid): 140 °C for 10 minutes with PSI pressure.
Polymerization can occur in any temperature. However, it is very slow below
70 °C, the best cure cycle is slow curing cycle because most of the conversion
of monomer to polymer occurs during the period of 70 °C and during this time
the dough itself may approach 100 °C due to polymerization exothermic
reaction.
The breakdown of benzoyl peroxide (initiator) occur at 65 °C heating slowly
produce fewer radical and produce polymer with high molecular weight, the
monomer boils at 100.3 °C so the dough must kept below this temp. To avoid
boiling of the monomer, so short cycle curing result in some gaseous porosity.
Before deflasking of the processed denture, the flask cooled to room
temperature. This may lead to set up the internal stresses within the denture
base since the coefficient of thermal expansion of acrylic is greater about 10
times than gypsum mold material (plaster or stone).
2
Injection molding technique
Complicated procedure requiring special flask and equipment in these
techniques, the wax pattern is spread and the material is injected to the mold,
this process allow injection of further material during polymerization to
compensate for shrinkage.
Intermediate cure acrylic: Its composition is compromised between hot and

cold cure acrylic, which mean both activator (heat and tertiary amine) are
necessary for breaking down (decomposition) of the BPO (Benzoyl peroxide)
initiator. The cure cycle is 20 min. at boiling water 100°C, this 20 min. will
avoid gaseous porosity but the degree of polymerization will be less than that
of hot cure. The intermediate cure acrylic appears attractive because of the
short curing cycle but its physical properties is less than hot cure.
Light cure acrylic: (light activated): Acrylic material may be activated by

exposure to light (could be visible light but mainly ultraviolet light) due to the
presence of certain initiator that sensitive or activated by this light.
Properties of acrylic denture base materials
Elastic moduli of polymers are much lower than materials (about 103kg/cm
while 107kg/cm for materials). The glass transition temperature. For hot cured
materials about 105°C while for cold cure 90°C, temperature. Above which
the material change rapidly to resins and soft, while below this it is very rigid
and hard glass like material.
Low specific gravity (1-2 g/cm)

Poor thermal conductivity (insulator) about 100-1000 less than metal.
Color stability of cold cure acrylic is less than that of hot cure because the
amine in cold cure tends to oxidize and produce yellowing of this resin within
the time.
Radiopacity: The polymer is radiolucent, the addition of barium sulfate make

the polymer slightopaque but the addition of metallic foil stripe make the
material radiopaque.
3
Strength: The strength of the acrylic denture base depend on the type of
polymer (composition) and the technique of producing, the higher the degree
of polymerization, the higher the strength.
Cold cure acrylic has less strength and stiffness than hot cure because of the
free radical monomer retained in denture base generally acrylic material have
poor compact strength and poor hardness.
Water absorption: acrylic denture base material slowly absorbed water by

diffusion of the water molecules between the macromolecules of the polymer,
this lead to slight expansion "Acrylic absorb and adsorb water so sorption may
use. Crazing, which is appearance of small crack (pseudo crack) on the surface
of the denture after a period of time this might be due to drying out of the
surface layer of the denture. This crazing lead to contraction and so residual
stress are formed across the surface and result in those fine cracks also these
cracks may be seen around porcelain teeth metal clasps due to the inability of
the acrylic to adhere to metals or porcelain. Therefore, the difference in
coefficient of thermal expansion between the acrylic and this material (metal
and porcelain) cause these cracks.
4
Difference between hot and cold cure acrylics
Hot cure Cold cure
a- Heat application activates the a-The polymerization reaction is
reaction of polymerization. activated chemically by the
presence of dimethyl p-Toluidine a
tertiary Amin activator.
b- Slower curing with less simple b- Faster curing with simpler mold
mold construction. construction with easier deflasking.
c- More strength and hardness. c- Less strength and hardness.
d- Color stability is higher. d- Color stability is less.
e- Dimensional stable during e- Dimensional stable is more.

processing is less.
f- The length of the molecular chain f- The length is less.
is greater.
g- Average molecular weight is g- Average molecular weight of
higher. lower.
h- Has less proportion of residual h- Has high proportion of residual
monomer. monomer.

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Dental Materials Assis. Prof. Dr.

Compressive technique includes: Preparation of the mold, the stone cast

Curing: Means polymerization to produce the final denture; pressure is

Intermediate cure acrylic: Its composition is compromised between hot and

Light cure acrylic: (light activated): Acrylic material may be activated by

Properties of acrylic denture base materials

Low specific gravity (1-2 g/cm)

Radiopacity: The polymer is radiolucent, the addition of barium sulfate make

Water absorption: acrylic denture base material slowly absorbed water by

c- More strength and hardness. c- Less strength and hardness.

d- Color stability is higher. d- Color stability is less.

e- Dimensional stable during e- Dimensional stable is more.

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