A1-Mould Production 100033 10.2015 Rev.1.0

WORK INSTRUCTION
MOULD PRODUCTION
UV TECHNOLOGY ITE PRODUCTION
S E R V I CE & P R O D U C T I O N S U P P O RT
BERNAFON AG
SWITZERLAND
Page 2 of 19
MOULD PRODUCTION
History
Date
2015-09-22
Rev. no
1.0
Comments
Page 9: Section Common guidelines to Gel mould production, comment for protruding parts updated.
Pages 11-15: Sections Impression preparation for gel mould: CIC/MIC; ITC Half Shell; ITE Half Shell; ITE Full Shell,
photos from modelling added.
Page 18: Information how many times gel can be re-used added.
100033
10.2015
REV. 1.0
S E R V I C E & P R O D U C T I O N S U P P O RT
BERNAFON AG
SW I T Z E R L A N D
WO R K I N ST R U C T I O N
ITE PRODUCTION
U V T EC H N O LO GY
Page 3 of 19
MOULD PRODUCTION
Table of contents
History ................................................................................................................................. Page 2
Common materials for Mould production ............................................................................... Page 4
Control mould production ..................................................................................................... Page 5
Common guidelines to Gel mould production ..................................................................... Page 9
Impression preparation for gel mould: CIC/MC ...................................................................... Page 11
Impression preparation for gel mould: ITC Half Shell .............................................................. Page 13
Impression preparation for gel mould: ITE Half Shell .............................................................. Page 14
Impression preparation for gel mould: ITE Full Shell .............................................................. Page 15
After trimming ...................................................................................................................... Page 17
Waxing of impression and gel mould production.................................................................... Page 18
100033
10.2015
REV. 1.0
BERNAFON AG
ITE PRODUCTION
Page 4 of 19
MOULD PRODUCTION
Common materials for Mould production

Description
Code No
Cutting plate
838-03-025-02
Knife, Stanley
825-20-100-00
Blades, Stanley (10 pcs.)
890-04-027-05
Miller, cylindrical 6.0 mm
890-20-067-08
Sandpaper, grit 180, width 15 mm, green
890-20-154-04
Holder for sandpaper
890-21-317-02
Wax knife (110V)
804-24-005-00
Wax knife (220V)
804-24-015-02
Correction wax, red (60 gr.)
788-01-120-07
Dipping wax, purple (500 gr.)
788-01-023-09
Form, large (4 pcs.)
890-21-376-04
Form, small
890-21-680-03
Gel fotogel (6 kg.)
792-10-040-07
Tweezers, angled
890-21-082-09
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10.2015
REV. 1.0
BERNAFON AG
ITE PRODUCTION
Page 5 of 19
MOULD PRODUCTION
Control mould production
Other styles
7 mm
CIC/MIC
12 mm
Ear line
1. The impression must be evaluated at the log-in step,
2. The impression must be:
before control mould production to ensure the best results.
Fully casted.
Compare impression with a. Requested instrument,
With the necessary style-canal length which is minimum
b. Req. style (enough space?)
12 mm for CIC and 7 mm for all other styles.

The ear line must be visible.
You can nd this infomation in the Work Order.
100033
10.2015
REV. 1.0
Remove
Only excess of material
3. Remove sponge or cotton wool from the canal tip.
4. Cut excess of material at the base of the impression and

make it at.
BERNAFON AG
ITE PRODUCTION
Page 6 of 19
MOULD PRODUCTION
Only excess of material
Order number
5. Cut only excess of material around the impression
6. Write order number on the impression (the same number
(concha side). Be careful not to cut too much on the Tragus
as on the Work Order).
side.
Perforated spoon
Wax, purple
Wax temperature
Down
100033
We recommend using the

purple dipping wax melted
at the temperature of
85-120 C
10.2015
REV. 1.0
Relevant imperfection
corrected
7. Fill up relevant lack of material (imperfection) on the
8. Place the impression on the perforated spoon. Deep the
impression using correction wax and the wax knife.
impression into the wax purple in one continuous and calm

movement. The impression must be lifted up just after it is
fully covered with wax.
BERNAFON AG
No excess of wax
9. After impression dipping, check that there is not excess of
10. Place the impression at the centre of the form.
wax on the points shown in the picture.
ITE PRODUCTION
Page 7 of 19
MOULD PRODUCTION
11. Fill the form with duplicating silicone Duglasil CFS, clear,
12. Place an identication label (order number) in the
using the silicone mixing machine. If you do not have the
silicone.
machine, mix the silicone in the ratio of 1:1 by stirring the

material in a cup and pour it in the form with the impression.
Impression covered
with silicone
100033
10.2015
REV. 1.0
13. Check that the control mould has no air bobbles (or
14. Let the silicone harden at room temperature
as few as possible) and that the impression is completely
(approx. 20 C) for 5 minutes.
covered with silicone material.
BERNAFON AG
Loose and
remove
Angled tweezer
Angled tweezer
Angled tweezer
Compressed air
15. When hardened remove the control mould from the form
16. a. Remove carefully impression from the control mould
by loosing it from the inside of the form.
using an angled tweezers. b. Remove wax from control

mould using compressed air.
ITE PRODUCTION
Page 8 of 19
MOULD PRODUCTION
Open canal tip
Same number as
Work Order
17. Cut excess of material on the control mould, on the
18. Check that the order number on the impression and in
concha side. Open the canal tip side of the control mould
the control mould is the same as on the Work Order.
being careful not to cut the canal length.
100033
10.2015
REV. 1.0
BERNAFON AG
ITE PRODUCTION
Page 9 of 19
MOULD PRODUCTION
Common guidelines to Gel mould production
Area visible
outside the ear
2886
2886
Ear line
1. The number on the impression must correspond to the
2. The area under the ear line correspond to the part of the
one on the order form and control mould.
instrument that will be visible outside the ear, therefore it

has to be trimmed as carefully as possible.
Canal end
for ITE
100033
Do not trim
10.2015
REV. 1.0
Part that locks

instrument in the ear
3. Remember never to trim the part of the ear canal which
4. Verify canal direction related also to style.
locks the instrument tight in the ear.
Correction
wax
BERNAFON AG
Trimmed area
5. If the canal end has protruding parts, then there is a need
6. If there is a big lack of material, ask for new impression or
to trim it as it is shown on the photo. Dont remove all
if this is not possible, correct the part missing material with
material from protruding parts. Leave small bump. It is
correction wax, following the canal end direction.
needed to keep instruments in the canal.
ITE PRODUCTION
Page 10 of 19
MOULD PRODUCTION
No excess of wax
Wax knife
7. Use wax knife at the temperature of 200-220 C.
8. Be careful not to overbuild the impression with wax.

Remember: excess of wax on impression cause a thick,
hurting shell in the control ear.
100033
10.2015
REV. 1.0
9. Use form.
10. The gel mould, after its purpose, can be re-used

2-4 times more beginning from the melting process
(see page 15, step 3 for more information).
BERNAFON AG
ITE PRODUCTION
Page 11 of 19
MOULD PRODUCTION
Impression preparation for gel mould: CIC/MC

Base of
impression
Cymba-Concha
Concha
Knife,
Stanley
1. Cut the base of the impression.
2. Cut the Concha straight through, where the Cymba-Concha

starts.
Excess of
material
100033
10.2015
REV. 1.0
Concha
3. Position the impression as shown in the picture and cut
4. Cut the Concha further if necessary and eliminate excess
the concha in the CIC angle.
of material.
2nd bend
2nd bend
1st bend
BERNAFON AG
2nd bend
1st bend
5. The impression for the CIC must have the rst and second
CIC placement in the ear.
bend. Cut the canal end tip just after the second bend.
If only the rst bent is present, cut as little as possible
keeping in mind the canal direction.
ITE PRODUCTION
Page 12 of 19
MOULD PRODUCTION
Impression preparation for gel mould: CIC/MC

Miller
cylindrical
6. Trim to eliminate excess of material.
100033
10.2015
REV. 1.0
BERNAFON AG
ITE PRODUCTION
Page 13 of 19
MOULD PRODUCTION
Impression preparation for gel mould: ITC Half Shell

Base of
impression
Cymba-Concha
Concha
Knife,
Stanley
1. Cut the base of the impression.
starts.
2nd bend
100033
90
1st bend
10.2015
2nd bend
REV. 1.0
3. Position the impression as shown in the picture. Cut the
4. Verify canal direction related also to style.
Concha in the ITC/ITE angle (90) and excess of material if

necessary.
Miller
cylindrical
BERNAFON AG
ITE PRODUCTION
ITC HS placement in the ear.
Page 14 of 19
MOULD PRODUCTION
Impression preparation for gel mould: ITE Half Shell

Base of
impression
Cymba-Concha
Concha
Knife,
Stanley
1. Cut the base of the impression

starts.
Cut excess of material

Cut
100033
90
1st bend
10.2015
1st bend
REV. 1.0
Cut
3. Position the impr. as shown in the picture and cut the
4. Cut the canal end tip just after the rst bend keeping in
Concha in the ITE Half Concha side angle (90) and excess
mind the canal direction.
of material if necessary.
Miller
cylindrical
BERNAFON AG
ITE PRODUCTION
ITE HS placement in the ear.
Page 15 of 19
MOULD PRODUCTION
Impression preparation for gel mould: ITE Full Shell

Ear line
Cut
parallel
Locking points
Locking
points
Knife,
Stanley
1. Mark locking points on the impression.
2. Cut the base of the impression parallel to the ear line

being careful not to go under it (the locking points must be
visible).
Cutting line
Cymba-concha
100033
Cutting
line
10.2015
REV. 1.0
3. Find the cutting line on the Cymba-Concha using control
4. Cut excess of Cymba-Concha and excess of material,
ear.
if necessary.
Cutting line
BERNAFON AG
1st bend
5. Cut the canal end tip just after the rst bend keeping in
FS placement in the ear.
mind the canal direction.
ITE PRODUCTION
Page 16 of 19
MOULD PRODUCTION
Impression preparation for gel mould: ITE Full Shell

Miller
cylindrical
100033
10.2015
REV. 1.0
BERNAFON AG
ITE PRODUCTION
Page 17 of 19
MOULD PRODUCTION
After trimming
Canal end
direction OK!
Fitting OK!
1. After trimming check for: Correct canal end direction in
2. Correct tting (no gap or pressure points) in the control
the control mould.
mould.
Locked in
the control mould
100033
10.2015
REV. 1.0
Cut angle OK!
3. Correct base cut/angle (Concha cut) in the control mould.

For full concha check that the base locks rmly the impression.
BERNAFON AG
ITE PRODUCTION
Page 18 of 19
MOULD PRODUCTION
Waxing of impression and gel mould production

Perforated spoon
Wax, purple
Wax temperature
Down
We recommend using the
purple dipping wax melted
at the temperature of
85-120 C
1. Place the trimmed-to-style impression on the perforated
2. Place the impression at the centre of the form.
spoon. Deep the impression into the wax purple in one

continuous and calm movement. The impression must be
lifted up just after it is fully covered with wax.
100033
10.2015
REV. 1.0
Temperature controled
gel machine
3. Prepare the gel (Fotogel): a. Melt it at the temperature
4. Fill the form with gel. Avoid air bobbles by starting from
of 92 C. b. Decrease temperature until 44-47 C. For this
the bottom-side of the form and lling up around the
process, use the temperature controlled gel machine.
impression.
Note: Gel mould can be re-used 2-4 times.
BERNAFON AG
ITE PRODUCTION
Page 19 of 19
MOULD PRODUCTION
Fill up if use of
ALC machine*
*) Automatic Light Curing

5. a. Remove air bobbles. b. Place an identication label
6. Let the gel mould harden: At room temp. (approx. 20 C)
(order number) in the gel. Note: Fill form up with gel if
for approx. 30-40 minutes or in the refrigerator for approx.
casting shell with ALC machine.
20 min.
Loose and
remove
100033
10.2015
REV. 1.0
Angled tweezer
Compressed air
7. When hardened remove the gel mould from the form by
8. a. Remove carefully impression from the gel mould using
loosing it from the inside of the form.
an angled tweezers. b. Remove wax from gel mould and dry

it using compressed air.
Cut only excess
BERNAFON AG
9. Cut excess of material on the gel mould, on the Concha

siden (if necessary).
ITE PRODUCTION

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WORK INSTRUCTION

Common materials for Mould production

Blades, Stanley (10 pcs.)

Miller, cylindrical 6.0 mm

Sandpaper, grit 180, width 15 mm, green

Holder for sandpaper

Wax knife (110V)

Wax knife (220V)

Correction wax, red (60 gr.)

Dipping wax, purple (500 gr.)

Form, large (4 pcs.)

Gel fotogel (6 kg.)

Control mould production

1. The impression must be evaluated at the log-in step,

2. The impression must be:

before control mould production to ensure the best results.

Compare impression with a. Requested instrument,

With the necessary style-canal length which is minimum

b. Req. style (enough space?)

12 mm for CIC and 7 mm for all other styles.

You can nd this infomation in the Work Order.

Only excess of material

3. Remove sponge or cotton wool from the canal tip.

4. Cut excess of material at the base of the impression and

Only excess of material

5. Cut only excess of material around the impression

6. Write order number on the impression (the same number

(concha side). Be careful not to cut too much on the Tragus

as on the Work Order).

We recommend using the

7. Fill up relevant lack of material (imperfection) on the

8. Place the impression on the perforated spoon. Deep the

impression using correction wax and the wax knife.

impression into the wax purple in one continuous and calm

9. After impression dipping, check that there is not excess of

10. Place the impression at the centre of the form.

wax on the points shown in the picture.

12. Place an identication label (order number) in the

using the silicone mixing machine. If you do not have the

machine, mix the silicone in the ratio of 1:1 by stirring the

14. Let the silicone harden at room temperature

as few as possible) and that the impression is completely

(approx. 20 C) for 5 minutes.

covered with silicone material.

16. a. Remove carefully impression from the control mould

by loosing it from the inside of the form.

using an angled tweezers. b. Remove wax from control

Open canal tip

17. Cut excess of material on the control mould, on the

18. Check that the order number on the impression and in

the control mould is the same as on the Work Order.

being careful not to cut the canal length.

Common guidelines to Gel mould production

1. The number on the impression must correspond to the

one on the order form and control mould.

instrument that will be visible outside the ear, therefore it

Part that locks

3. Remember never to trim the part of the ear canal which

4. Verify canal direction related also to style.

locks the instrument tight in the ear.

5. If the canal end has protruding parts, then there is a need

6. If there is a big lack of material, ask for new impression or

to trim it as it is shown on the photo. Dont remove all