Dental Materials Journal 2010; 29(4): 411–417

Comparative adaptation accuracy of acrylic denture bases evaluated by two

different methods
Chung-Jae LEE1,2, Sung-Bem BOK1, Ji-Young BAE1 and Hae-Hyoung LEE1,3
1
Department of Biomaterials Science, Dankook University, School of Dentistry, San-29 Anseo, Cheonan 330-716, Korea
2
Department of Dental Technology, Shinheung College, 117 Howon, Uijeongbu 480-701, Korea
3
Institute of Tissue Regeneration Engineering, Dankook University, San-29 Anseo, Cheonan 330-714, Korea
Corresponding author,  Hae-Hyoung LEE;  E-mail:  haelee@dku.edu


This study examined the adaptation accuracy of acrylic denture base processed using fluid-resin (PERform), injection-moldings (SR-
Ivocap, Success, Mak Press), and two compression-molding techniques. The adaptation accuracy was measured primarily by the
posterior border gaps at the mid-palatal area using a microscope and subsequently by weighing of the weight of the impression
material between the denture base and master cast using hand-mixed and automixed silicone. The correlation between the data
measured using these two test methods was examined. The PERform and Mak Press produced significantly smaller maximum
palatal gap dimensions than the other groups (p<0.05). Mak Press also showed a significantly smaller weight of automixed silicone
material than the other groups (p<0.05), while SR-Ivocap and Success showed similar adaptation accuracy to the compression-
molding denture. The correlationship between the magnitude of the posterior border gap and the weight of the silicone impression
materials was affected by either the material or mixing variables.

Keywords: Acrylic denture base, Adaptation accuracy, Correlationship



gap11-16) and weighing a elastomeric material impressed

INTRODUCTION
Among the polymer materials introduced in prosthetic
dentistry, Polymethyl methcrylate (PMMA) is the only
proven material for a successful denture base on
account of its optimal physical properties and excellent
esthetics with relatively low toxicity compared to other
plastic denture bases1-3). A long-established method for
denture processing for acrylic polymer is a closed-flask
compressing molding with heat activation in a water
bath for resin polymerization2). However, polymerization
shrinkage of the resin and distortion of the denture
base due to thermal stress is virtually unavoidable
during the processing of dentures. These adverse effects
cause movement of the artificial teeth position and
increase the gap between the denture base and
underlying mucosa, resulting in an ill-fitting denture4-6).
It has been suggested that an accurate fitting is a key
factor in the physical mechanisms of complete denture
retention7,8).
Several alternative methods to conventional
compression-molding processing for denture base have
been developed to increase the adaptation of the
denture base, such as injection-molding9) and fluid-
resin10) techniques. Recently, many manufacturers have
introduced newer denture processing systems using
light-curable and microwave-curing resins2). Therefore,
the adaptation accuracy or dimensional changes in the
denture bases has become a focus of many studies in
removal prosthodontics.
A variety of methods have been used to evaluate
the dimensional changes and/or adaption accuracy of a
denture base, there is still no gold standard.
Microscopic measurements of the posterior border
under a denture base11,17-19) are one of the most
frequently used methods to evaluate the denture
adaptation to a master cast due to their simplicity and
feasibility. The magnitude of the palatal border gap can
express the ability of a border seal, and the weight of
an impression material indicates the overall volume of
internal space under denture base, which are all
important factors in complete denture retention8). A
reasonable correlationship between the results of both
parameters can be expected for a well-fitted denture
base. However, much of previous results regarding the
adaptation accuracy of a denture base with variations
in the test method are inconsistent20).
This study compared the adaptation accuracy of a
maxillary complete acrylic denture base processed
using fluid-resin, injection-molding, and conventional
compression-molding techniques. Methods of direct
measurements of the posterior palatal border gap and
weighing the impression material between the denture
and master cast were used to evaluate the adaption
accuracy of denture base specimens. A correlation
between the data measured using these two different
test methods was investigated in this study.
MATERIALS AND METHODS
Preparation of denture base sample
The adaptation accuracy of denture bases conducting
should be measured using specimens with the same
size and shape for comparison. In order to fabricate
uniform dentures, thirty-six master casts were made
from a silicone negative replica (U-402, Nissin, Kyoto,
Japan) for maxillary complete edentulous arch using a

Received Oct 23, 2009: Accepted Mar 12, 2010

doi:10.4012/dmj.2009-105 JOI JST.JSTAGE/dmj/2009-105
412 Dent Mater J 2010; 29(4): 411–417

high-strength stone (Fujirock, GC, Belgium) (Fig. 1).

The impression was taken from each master cast using
a resin individual tray (Quicky, Nissin Dental, Japan)
and polyether impression material (Impregum, 3M
ESPE, Germany). A yellow stone (Neo Plumestone,
Mutsumi, Japan) was poured into the impression to
make the respective working cast for denture
processing. One complete wax denture was formed on
the master cast using base plate wax. The palatal base
was adapted using one layer of baseplate wax (Hard
wax, Daedong, Korea) at a uniform thickness of 1.7
mm.
It was reported that the adaptation accuracy of the
upper denture base can be influenced significantly by
the existence of denture teeth4,5,18). Therefore,
anatomical artificial teeth (#264 for anterior, 32M for
posterior, Biotone, Dentsply, USA) were arranged in
the wax denture. The wax denture-cast set was
impressed with a silicon putty impression material Fig. 1 A silicone negative replica for maxillary
edentulous arch and high-strength stone master
(Exafine, GC, Tokyo, Japan) to make the index mold for
cast.
reproducing the wax denture. The putty mold with
denture teeth positioned in the indexed places was
carefully seated on each working cast. The wax denture
was completely reproduced by injecting molten
baseplate wax into the mold space through two holes
prepared on both alveolar ridge ends (Fig. 2).
Total thirty-six wax dentures on working casts
were prepared for this study. The wax dentures with
their respective master casts were divided into six
groups of different denture processing systems. One
group of denture bases was processed using the fluid-
resin technique (PERform-Inkovac-system, Hedent,
Germany). Three groups were processed by their
respective injection-molding techniques; SR Ivocap
Injection system using High impact resin (Ivoclar,
Liechtenstein), Success injection system with Luciton
199 (Dentsply, USA), and Mak Press (Saitama, Japan)
with Vertex RS resin (Vertex, Zeist, Netherlands).
Another two groups were processed by compression-
molding using the silicon-gypsum technique at two
different curing cycles in a bronze flask. The wax
denture was covered with silicone putty (Platinum95,
RO, Italy) without the cusp tips of resin teeth. The
overall procedure was similar to that used by Becker et
al.21). The dentures were polymerized with Vertex RS
resin at 74°C for 9 hours (slow curing cycle) or by
boiling in water for 30 minutes (fast curing cycle). Six
maxillary complete dentures for each group were
prepared using the respective special equipment
according to the manufacturer’s instructions. Table 1
provides detailed information on the denture base
materials and processing techniques.
After polymerization, the curing flasks were bench-
cooled to room temperature, and the denture samples
were retrieved from the working cast. All injection
spruces and small flashes were removed carefully and
the denture bases were polished with a wet rag wheel Fig. 2 Silicone putty mold with denture teeth positioned
in the indexed places (a) and the reproduced wax
and pumice. All dentures were cleaned and stored in
denture (b).
distilled water at 37°C for 14 days before the
measurement.
 Dent Mater J 2010; 29(4): 411–417 413

Table 1 Fabrication systems for denture base and processing techniques

Product/ Batch no. Powder/Liquid Polymerization
Group Processing type
Denture resin Powder/Liquid ratio procedure
PERform-Inkovac- PER FB07681/ Fluid-resin 30 g/21 ml Pouring in vacuum,
System (Hedent, JI19736 Chemical activation Pressurized bath at
Germany)/Inkovac 6-bar/45°C
pouring resin

SR-Ivocap Injection IVO K44278/ Injection-molding 20 g/30 ml Air-pressing at 6-bar,

System (Ivoclar, K09925 Heat activation boiling in water for
Liechtenstein)/High 30 min
impact standard kit

Success® Injection SUC 051208/ Injection-molding 21 g/10 ml Air-pressing at 6 bar,

System (Dentsply, 060207 Heat activation heat curing at 73°C
USA)/Luciton 199 for 9 h
(Dentsply)

Mak Press (Toho Inc., MAK YN452P02/ Injection-molding 23 g/10 ml Air-pressing at 8 bar,
Japan)/Vertex RS YK482L01 Heat activation heat curing at
(Vertex dental, induction range for
Netherlands) 30 min

Conventional Heat- CMS YN212P02/ Compression-molding 23 g/10 ml Pack and press, heat
curing/Vertex RS YK211L06 Slow heat activation curing at 74°C for 9 h
(Vertex dental, at Hanau bath
Netherlands)

Conventional Heat- CMF YN212P02/ Compression-molding 23 g/10 ml Pack and press,

curing/Vertex RS YK211L06 Fast heat activation boiling in water for
(Vertex dental, 30 min
Netherlands)

Measurement of adaptation accuracy

To observe the overall gap formation of the denture
base, one denture placed on the respective master cast
for each group was scanned by computerized
tomography (CT). The CT images were obtained at a
scanning interval of 0.6 mm from the anterior to
posterior areas using 64 channels MD-CT (Light Speed
VCT, GE, USA). The frontally-sectioned images of the
denture-cast set and sagittal images reformed at the
palatal midline were obtained from the CT data.
For the posterior palate border gap measurements,
the denture base placed on the respective master cast
was trimmed to a horizontal line 5-mm away from the
posterior end using a vertical trimmer (MT2, Renfert,
Germany) with a diamond disc under water cooling.
The cut surfaces were polished using P# 1,000 SiC
abrasive paper to allow a visual distinction. Digital Fig. 3 Measurement of the maximum palatal border gap
(Pmax) and vestibule gap (V1 and V2) between the
images were then captured at the area of mid-palatal
denture base and master cast.
line and buccal vestibules using a zoom
stereomicroscope (SMZ-1500, Nikon, Tokyo, Japan)
with 3.0 megapixel CCD camera (Moticam 2300, Motic,
Hong Kong) at a ×125 PC-monitor magnification. gap (V) in micrometer resolution (Fig. 3). For
Whilst capturing the images, the denture bases were consistency, two examiners checked all measurements
positioned on their master casts by fixing with two simultaneously. The dimension, V, was determined
clothespins exerting a 10-N force. Calibrated image from the mean of both vestibule gaps (V=(V1+V2)/2).
software (Motic Images Plus 2.0) was used to measure The gaps at the top of alveolar ridges and palatal slope
the maximum border gap (Pmax) within a 5-mm range were not measured due to difficulties in obtaining
at the posterior palatal midline and deepest vestibule accurate readings22).
414 Dent Mater J 2010; 29(4): 411–417

As a secondary evaluation of the adaption accuracy, However, the gap distance or volume could not be
the weight of the low viscosity silicon materials measured from the CT images due to the low
impressed on the respective master cast was measured resolution.
for all dentures. First, white silicone for fit checking Table 2 summarizes the posterior border gaps at
(Fitchecker II, GC, Tokyo, Japan) was hand-mixed the area of the mid-palatal line (Pmax) and buccal
thoroughly at equal lengths of the base and catalyst for vestibule (V), as well as the weights of the impression
20 seconds, and placed on the tissue side of the materials. One-way ANOVA revealed a significance
denture. The denture base with the impression paste difference between the groups at each of the evaluation
then seated on the master cast and positioned on a results. The Tukey’s post-hoc multiple comparisons test
constant loading apparatus (A-001, MECC, Tokyo, showed significantly smaller Pmax values for the fluid-
Japan) with a load of 49-N from the master cast. After resin group PER and an injection-molding group MAK
5 minutes, the load was removed and the excess than those of the other groups (p<0.05). Similarly the V
material beyond the denture base was trimmed from values of the PER and MAK groups were smaller than
the entire denture periphery with a scalpel. Then the the other groups. Group MAK produced a significantly
set silicone material was carefully peeled away from smaller mean weight of automixed silicone impression
the denture base and weighed immediately on an material (AS). There was no significant difference in
analytical balance (Voyager, Ohaus, NJ, USA) to a the adaptation accuracy between the compression-
level of 0.1 mg. The procedure was repeated twice for
each denture and the average weight of the impression
material is expressed as the adaptation accuracy of the
denture base.
After two days storage of the dentures in water,
the weighing procedure of the impression material was
repeated using an automixed polyvinyl siloxane light
body (Perfect-F, Handae, Korea) with an auto-mixing
gun to prevent possible error from imperfect mixing or
an inconsistent mixing ratio of the silicone material.
However, the weight of the automixed silicon impressed
was measured only once.
The adaptation accuracy for the sample groups was
examined by an analysis of variance (ANOVA) with a
Tukey’s multiple comparisons test at p<0.05 level. The
correlationship of data between the gap measurement
and weight of silicone for all thirty-six dentures was
examined using Pearson’s correlation test.

RESULTS
Figure 4 shows the CT images reformed at the mid-
sagittal line of denture bases on the respective master
cast. For all dentures, gap formation between the tissue
surface of the denture base and master cast increased
from the anterior to posterior side of plate and also Fig. 4 Computerized tomography images for each
from the alveolar ridge to the mid palatal line. denture at the mid-sagittal line.

Table 2 Mean values and standard deviations for the maximum posterior border gap (Pmax) and vestibule gap (V), and
the weight of hand-mixed silicone (FC) and auto-mixed silicone (AS) impression materials
Posterior border gap (µm) Weight of impression materials (g)
Denture group
Pmax V FC AS
PER 210 (112) a
284 (66) a
2.01 (0.09) ab
2.15 (0.17)b
IVO 427 (116) b
584 (85) b
2.00 (0.11) ab
2.35 (0.10)b
SUC 406 (145)b 527 (121)b 1.82 (0.13)a 2.19 (0.28)b
MAK 234 (53) a
375 (71) ab
1.78 (0.02) a
1.50 (0.20)a
CMS 419 (57)b 547 (189)b 2.15 (0.18)b 2.61 (0.22)c
CMF 375 (91) b
580 (198) b
2.18 (0.26) b
2.11 (0.12)b
Standard deviation in parentheses.
Mean values superscripted by the same letter at each parameter are not significantly different (p>0.05).
 Dent Mater J 2010; 29(4): 411–417
Fig. 5 Correlation between the maximum palatal border
gap (Pmax) and vestibule gap (V).
Fig. 6 Correlation between the maximum palatal border
gap (Pmax) and weight of hand-mixed silicone (FC).
Fig. 7 Correlation between the maximum palatal border
gap (Pmax) and weight of auto-mixed silicone (AS).
415
molding groups (CMS and CMF), except for the weight
of AS.
Figures 5-7 show the correlation plots of Pmax as a
function of the vestibule gap (V), weight of the hand-
mixed silicone (FC), and automixed silicone (AS) with
their respective Pearson’s correlation coefficient (PC).
The Pmax value revealed a moderate but significant
correlation with the V value (PC=0.633, p<0.01) and
weight of AS (PC=0.434, p<0.01). However, there was
little correlation between the Pmax value and the weight
of FC (PC=0.167, p>0.05).
DISCUSSION
Gap formation between the denture base and cast are
generally attributed to polymerization shrinkage of the
resin material and a tendency of cooling shrinkage
toward the central area of the denture base, as well as
to subsequent distortion caused by confinement of the
surface topography of the alveolar ridge23). Therefore,
the greatest gap will generally be observed in the
central portion of the posterior border and buccal
vestibule area, while the contact state around the ridge
crest remains stable. The CT images of individual
denture base-cast set did show this tendency of gap
formation in medial-lateral and anterior-posterior areas
(Fig. 4). These findings are also predictable with the
results reported by Consani et al.15), who compared the
posterior border gap of the denture base-cast sets
sectioned transversally at each area of the canine,
molar and posterior ends. Moreover, the magnitude of
the posterior border gap generally increased medially
along the palatal vault reaching a maximum at the
midline of the plate11-13). These results suggest that the
overall internal adaptation of the denture base can be
evaluated simply from the maximum border gap (Pmax)
at the mid line of the posterior plate23-26). The
magnitude of the vestibular gap (V) showed a somewhat
stronger correlation with that of Pmax11,12), as shown in
this study (Table 2, Fig. 5).
Two injection-molding denture groups (IVO and
SUC) had a similar degree of Pmax and V gaps to the
compression-molding groups (CMS and CMF), and also
showed a similar weight of the impression materials.
These results are in general agreement with previous
results4,5,22,27) reporting no significant difference in
internal adaptation between the denture bases
processed using injection-molding (IM) and
compression-molding (CM) techniques. The IM denture
has known to produce a less increase in vertical
dimension of occlusion than CM denture28-30), which
caused by movement of artificial teeth during
processing. However, a minor change in the vertical
dimension is probably not related directly to adaptation
accuracy of a denture base, because their horizontal
dimension changes (anterior-posterior or medio-lateral)
are not different between the IM denture and CM
denture29,30).
However, one injection-molding denture, MAK,
showed a better accuracy of fit than the other injection-
416 Dent Mater J 2010; 29(4): 411–417
Fig. 8 Mak Press denture base with three forked sprues
after deflasking.
molding and conventional groups. Moreover, MAK
produced the least mean weight of both impression
materials showing excellent internal adaption of the
denture base. Only Matsumura et al.24) reported the
adaptation accuracy of the MAK by measuring the
posterior palatal gap. Although they used different
resin base materials to this study, the posterior palatal
gap (227±38 µm after 14 days storage in water) at the
palatal midline of MAK was similar to the present
result (234±53 µm), which showed better adaptation
than some compression-molded denture bases. The
MAK denture is polymerized in the induction-heating
range and formed by injection molding through a
gateway formed by three forked wax sprues attached
vertically to the denture base of the palatal area (Fig.
8), which was originally introduced by Prior9). Unlike
other injection molding systems, vertical injection
against the denture base is probably attributable to the
higher adaptation accuracy of the MAK denture.
The fluid-resin processing system with an
autopolymerizing resin (PER) produced significantly
smaller Pmax and V dimensions than those of the other
groups. It has been reported that autopolymerizing
resins, including PER, produce a denture base with a
more accurate fit7,11,31). However, the weight of the
impression materials (FC and AS) of PER in this study
was not lower than those of other groups. This might
be explained by the relatively lower ability of a detailed
reproduction by fluid-resin processing32), possibly due to
the lack of resin packing pressure.
In previous data27), the magnitude of mean total
volume of space between the denture base and master
cast (as measured by the moiré topography) well
correlated with the respective mean weight of the
impression materials for four different denture systems,
although the correlation between these data for
individual samples was unknown in the study.
However, in the other report11) on the adaptation
accuracy of six different dentures measured by
weighing an impression material and subsequent
optical measurements, the rank order of mean values
for the denture groups was not the same for both
measurement methods.
In the results of present study, there was a
statistically significant positive correlationship between
the maximum border gap, Pmax, and the weight of an
automixed silicone (AS) for all denture specimens in
the six groups (Figs. 6 and 7, n=36). However, the
strength of correlation (PC=0.434) was moderate,
suggesting that there may be uncertain factors in
comparing both methods for an evaluation of the
adaption accuracy. Moreover, a poor correlationship
was observed between the weight of hand-mixed
silicone (FC) and Pmax. This result might be due to the
difference in the mixing procedure and/or in viscous
changes after applying the load of the impression
materials. Although a standardized process in the
weighing the impression material for evaluating
denture adaptation has emphasized11,18), further
variables, such as the mixing ratio, type of material,
viscoelastic behavior with time and temperature, and
applied load should also be considered33).
The previous results reported an increase in the
weight of the impression material trapped under the
denture base after storage in water for 14-30 days19,34),
while the maximum palatal gap of several denture
bases decreased after storage in water for more than 14
days24). Therefore, a repeated measurement method for
weighing impression materials of the denture base may
produce an incorrect measure of the adaptation
accuracy. In our preliminary study, a considerable
increase in Pmax was observed when it was measured
after measuring the impression material (data not
shown). It is recommended that the measurement of
the gap dimensions of the denture base should be
conducted primarily before weighing the impression
material, as in this study.
The clinical significance of the adaptation
inaccuracy measured in a denture base-cast set is
controversial22). Moreover, consideration of factors other
than the adaption accuracy have been advocated in the
selection of denture processing system21,22). However,
newer denture materials and processing techniques
are being introduced continuously because the
contemporary technique for denture fabrication are still
unsatisfactory35). A relatively higher fit of the denture
base may be helpful in reducing the initial adaptation
period of the denture wearer. A further standardized
method for comparing the adaptation accuracy of the
denture base with well-controlled clinical comparison is
needed. Micro-CT was successfully used to measure the
marginal fit of a dental ceramic crown36). This
nondestructive examination can be more constructive
method to evaluate the adaptation accuracy of denture
base.
 Dent Mater J 2010; 29(4): 411–417 417

19) Sartori EA, Schmidt CB, Mota EG, Hirakata LM, Shinkai
ACKNOWLEDGMENTS RS. Cumulative effect of disinfection procedures on
microhardness and tridimensional stability of a poly(methyl
This study was supported by Priority Research Centers
methacrylate) denture base resin. J Biomed Mater Res B
Program through the NRF of Korea funded by the 2008; 86: 360-364.
Ministry of Education, Science and Technology (No. 20) Haug SP, Duke P, Dixon SE, Menegotto LD, Zentz RR,
2009-0093829). Moore BK. A pilot clinical evaluation of a new injection
denture base system. Compend Contin Educ Dent 2001; 22:
847-852, 854, 856.
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