Failures of RPD

FAILURES OF REMOVABLE
PARTIAL DENTURE
“Laboratory Errors And Their Possible Treatment”
Polykarpos Memy Mahrous

INTRODUCTION
 For the construction of an accurate RPD that

is successful in patient's mouth, a
combination of many planned steps is a must.
 So, to understand the ERRORS that may lead

to failure in the construction of the RPD, the
ideal prerequisites for each step of laboratory
RPD construction must be known .
OUTLINE
1. Special tray construction. 12. polishing of metal framework.
2. Surveying. 13. Refitting.
3. Master cast preparations. 14. Mounting to articulator.
4. Duplication. 15. Teeth selection.
5. Wax Pattern Formulation. 16. Teeth arrangement.
6. Spruing. 17. Waxing up.
7. Investing. 18. Packing acrylic resin.
8. Burn-out. 19. Curing.
9. Casting. 20. De-flasking.
10. De-vesting. 21. Finishing.
11. Finishing of metal framework. 22. Polishing.
OUTLINE
1. Special tray construction. 12. polishing of metal framework.
2. Surveying. 13. Refitting.
3. Master cast preparations. 14. Mounting to articulator.
4. Duplication. 15. Teeth selection.
5. Wax Pattern Formulation. 16. Teeth arrangement.
6. Spruing. 17. Waxing up.
7. Investing. 18. Packing acrylic resin.
8. Burn-out. 19. Curing.
9. Casting. 20. De-flasking.
10. De-vesting. 21. Finishing.
11. Finishing of metal framework. 22. Polishing.
SPECIAL TRAY CONSTRUCTION:
 Ideally, a special tray should provide

accurate fitting in patient's mouth
with even space for the
impression material.
SPECIAL TRAY CONSTRUCTION:
 Errors resulting and their possible treatment
Defective impression
▪ it is important to obtain an accurate master cast for
construction of the metallic framework and the acrylic
resin to be packed in a form that provides adequate
support
▪ So, accurate special tray will help in obtaining
accurate impression that gives accurate casting in the end.
OUTLINE
1. Special tray construction 12. polishing of metal framework
2. surveying 13. Refitting
3. Master cast preparations 14. Mounting to articulator
4. Duplication 15. Teeth selection
5. Wax Pattern Formulation 16. Teeth arrangement
6. Spruing 17. Waxing up
7. Investing 18. Packing acrylic resin
8. Burn-out 19. Curing
9. Casting 20. Deflasking
10. De-vesting 21. Finishing
11. Finishing of metal framework 22. polishing
SURVEYING
A. Selecting a defective path of insertion
 Either unintended tilting, tilting to create
undercuts, or made to avoid certain interferences.
 This change in path of insertion changes:

- The survey line,
- Angulation of block out,
- Location of clasp tips.
Thus, changing the whole design
SURVEYING
A. Selecting a defective path of insertion

 If the technician noticed the problem, he should
re-select the path of insertion. Then, new
survey lines and design should be formulated.
 If the technician proceeded with the defective

path of insertion, it will be difficult to repair and
a new framework might be needed.
SURVEYING
B. Desirable undercuts errors

▪ Unaware technician may locate the clasp tip:
• too close to gingival margin "damage to oral tissues"
• too near to the survey line "less retentive“
▪ Also the technician may choose a clasp that is not

suitable for the properly measured undercut
"e.g. rigid clasp arm used in deep undercut"
SURVEYING
B. Desirable undercuts errors

- If any of the situations mentioned
occurred , the casted clasp may be cut
and replaced with another one "either
casted or wrought wire" at the stage of
final try-in
OUTLINE
MASTER CAST PREPARATION
A. Deep Beadings
 This error is diagnosed at try-in stage as
pain at palate or may be diagnosed in
follow up visits as laceration.
 It is easy to be located by the use of PIP and
easy to repair using air driven handpiece.
B. No Beadings
 This will result in a smooth fitting surface of major
connector that may cause food entrapment , with
no reference for its borders at the time of finishing.
 No possible repair.
C. Block out errors
▪ Under blocking of undesirable undercuts will lead to a
framework with interferences during insertion and removal
▪ Such errors may vary from:

- minor interference that needs just adjustment using
handpiece
- to major ones that may lead to remake of the framework
D. Errors related to relief

▪ Missed relief to prominent landmarks will lead
to pain under theRPD.
▪ Relief to gingival margins is of much great
importance as it may lead to laceration and
recession if overlooked.
▪ such a problem is easy to fix using PIP.
D. Errors related to relief

- Missing tissue stops may lead to sinking of
the framework during packing of acrylic
resin in the flask.
- Simply this error can be treated by placing
self cure resin stop between the framework
and the ridge at time of packing
OUTLINE
DUPLICATION
A. Using expired agar

B. Not cool enough agar
C. Delayed pouring
D. Investment errors
DUPLICATION
A. Using expired agar

- Agar as a hydrocolloid posses syneresis, which means it
loses water by time.
- Water must be added to the duplicating agar to substitute
the lost amount during the previous use.
- Ignoring this will result in viscous agar that lacks accuracy
of registering details.
DUPLICATION
B. Not cool enough agar error

- If agar was poured in the duplicating
flask with temperature exceeding 60˚C,
the wax of the master cast preparation
may melt down deteriorating the mold
surface.
DUPLICATION
C. Delayed pouring
- After creating the agar mold, the
investment must be poured directly to
avoid any dimensional changes that may
occur.
OUTLINE
WAX PATTERN FORMULATION
Careless wax pattern

 This may result in a pattern that is not
adapted to the cast.
 Thin wax sections , sharp angles, wrong
position of clasp arm are other technical
errors that may take place too.
WAX PATTERN FORMULATION
▪ Unfortunately, errors of under waxing in

this step are impossible to treat especially if
located at critical areas and they usually
result in incomplete casting.
▪ Over-waxing is difficult to treat, too. But if
it results in interference during insertion
and removal, it may be easier to treat by
grinding.
OUTLINE
SPRUING
- Usually faulty spruing results in short casting that
may be a result of :
▪ using small diameter sprues,
▪ too long ones,
▪ sharp bent channels,
▪ faulty positioning and connection.
- Unfortunately, there is no treatment for short casting
except for remake.
OUTLINE
INVESTING
Pimpled casting
- This error is related to the quality of adaptation of
investment material to the wax pattern surface
- Entrapment of air bubbles during investing will
lead to pimples on the framework surface.
- If such pimple is located on critical area "e.g. clasp
tip" it may cause the technician to re-cast the
framework
OUTLINE
BURN-OUT
A. Under heating
- This may result in incomplete wax elimination.
- in many situations, under heating will result in
incomplete casting which has no treatment except
for remake.
BURN-OUT
B. Over heating
- This leads to unnecessary hygroscopic
expansion and disintegration of the
investment material resulting in faulty
framework dimensions.
OUTLINE
CASTING
Incomplete casting
▪ This will result from :
₋ insufficient amount of metal.
₋ under melting of the metal ingots.
₋ waiting too long before throwing the metal in the ring.
₋ insufficient centrifugal force for casting.
▪ As mentioned before, under casting has no treatment but
remake
OUTLINE
DE-VESTING
Warpage of framework may occurs due to:

▪ excessive pressure is used to remove the
investment material.
▪ over sand blasting .
DE-VESTING
Warpage of framework
- It may vary from minor changes in certain points
"clasp or minor connector" to major problem
"bent lingual bar major connector"
- if the fitting of the framework to master cast is
affected to a degree that is not correctable, the
framework should be discarded and a new one
should be reconstructed
OUTLINE
FINISHING OF METAL FRAMEWORK
Cutting off critical components
- Careless finishing may lead to injury to a
clasp body or occlusal rest to a degree making
them too weak to withstand forces in patient's
mouth.
- In such a case, the affected clasp may be cut

and replaced by a new one "soldered or
attached to the base"
OUTLINE
POLISHING OF METAL FRAMEWORK
A. Warpage of framework
- Excessive polishing will elevate the temperature of the
metal framework leading to its warpage
B. Thinning of framework
- Excessive electro-polishing of the framework will lead to
thinning of the metal especially at areas of junction
between different components
- Sadly, if this took place it will be unrepairable
OUTLINE
RE-FITTING FRAMEWORK TO MASTER CAST
Pseudo fitting
- This results when the framework is forced to fit the
cast without trimming the actual interferences in
its fitting surface.
- the cast gets scratched and the interference point
creates a pathway for itself.
RE-FITTING FRAMEWORK TO MASTER CAST
Pseudo fitting
- This error is then faced during framework try-in
in patient's mouth.
- trimming of the interfering area will be enough
to solve this problem.
OUTLINE
MOUNTING TO ARTICULATOR
Wrong centric relation
- Although it might be due to clinical fault, but it
also may happen due to careless mounting
- the try-in of the full RPD in patient's mouth will
show inability to reach a maximum
intercuspation
- The treatment of this problem is to re-record
centric relation, then re-set the teeth in the
correct position
OUTLINE
TEETH SELECTION
Errors resulting and their possible treatment

A. Faulty shade
B. Faulty size or form
C. Faulty size and form of posterior teeth
TEETH SELECTION
A. Faulty shade
- It is very related to clinical choice of shade, but the
technician may pick the wrong shade when setting
the anterior teeth
- It is very easy to treat by replacing the teeth after
the try-in stage
TEETH SELECTION
B. Faulty size or form
 Careless choice of the anterior teeth may also
result in errors related to the size of the teeth
selected.
 This is very common with resorbed anterior ridges.
 It is still easy to repair after try-in stage by replacing
the teeth.
TEETH SELECTION
C. Faulty size and form of posterior teeth
 The form of the posterior teeth is always related
to cutting efficiency.
 The bucco-lingual dimensions of the posteriors is
related to the stability of the RPD and the denture
base
 Faulty choice of form or size will lead to
accelerated alveolar ridge resorption by the
unnecessary stresses.
OUTLINE
TEETH ARRANGEMENT
A. Far labial arrangement

- This results in exaggerated lip fullness with pseudo
short lip manifestations
- Such error will damage the alveolar ridge leading to
its rapid resorption .
- This error must be corrected at time of try-in stage
by re-setting the anterior teeth
TEETH ARRANGEMENT
B. Posteriors out of the crest

- setting the posteriors out of the crest will
diminish the stability of the RPD leading to
unnecessary stresses on the ridges leading to
their resorption
- This error must be corrected at time of try-in
stage, too
OUTLINE
WAXING UP
A. Under waxing
- This leads to insufficient support to the checks
and lips
- It also will produce a denture base with thin
margins that are having diminished mechanical
properties
- To treat such an error, re-basing might be
needed
WAXING UP
B. Over waxing
- This leads to labial fullness .
- It also results in thick denture base margins
- It is easy to treat especially if the base is not so big
by trimming the outer surface of the denture base
OUTLINE
PACKING ACRYLIC RESIN
Errors resulting and their possible treatment
A. Delayed packing
B. Under packing
C. Early packing
D. Over packing
E. Teeth movement
F. Teeth fracture
G. Color streaks in the resin
A. Delayed packing
- This will occur when the acrylic resin is used in the
rubbery stage.
- The acryl in this stage will need over compression
resulting in accumulation of internal stresses
leading to warpage
- The treatment of such an error is not to do it
B. Under packing
- Under packing results due to insufficient amount of
packed acrylic resin in the mold
- It is manifested by short flanges or separated
artificial teeth
- Under packing has no treatment except for re-basing
C. Early packing
- Occur when the acrylic resin is packed in
the stringy stage
- Predisposes to porosity of the acrylic resin.
- Has not treatment except for re-basing
D. Over packing
- Occur when excessive amounts of acrylic resin is
packed in the mold
- It is usually accompanied by over compression
leading to teeth fracture or movement
- If the denture base remain unworped, the
affected teeth can be re-attached by self cure
acrylic resin
E. Teeth movement
This Occur due to :
▪ incomplete closure of the flask,
▪ using plaster instead of stone in investing the RPD.
▪ over compression or over packing.
F. Teeth fracture
This Occur due to:
- Delayed packing,
- Over compression,
- Setting the teeth directly on the framework
G. Color streaks in the resin
₋ This Occur due to :
▪ when the resin is improperly mixed, or
contaminated by dirt from the cup
▪ It may result from under packing when trying
to add new material to the mold to fill in the
spaces
₋ Treated by re-basing.
OUTLINE
CURING
Errors resulting and their possible treatment:

A. Porosity
B. Bleaching of the acrylic resin
C. Separation of teeth from the base
CURING
A. Porosity
- Porous denture is difficult to clean and
esthetically unacceptable
- Porosity may take place due to rapid heating, or
lack of pressure during polymerization.
CURING
B. Bleaching of the acrylic resin

Takes place due to
- under curing,
- contamination of the resin by the wax solvent,
- incorporation of the cellophane into the resin.
CURING
C. Separation of teeth from the base

 Occurs mainly due to delayed curing .
 or applying separating medium to teeth.
OUTLINE
9. Casting 20. De-flasking
DE-FLASKING
Breakage of teeth and/or denture base

- Occur when the de-flasking knife or the hammer
hits teeth during removal of stone cap.
- In such a situation, the fractured segments can be
re-assembled using self cure acrylic resin.
OUTLINE
FINISHING
A. Over heating
 As the rotary burs are used to finish the acrylic
resin, a rise in temperature takes place due to
friction
 Careless technician may ignore over heating thus
leading to warpage of the denture base
 This error is avoided by cooling the base in water
during finishing
FINISHING
B. Over trimming
- As the technician proceeds in finishing, he
might over trim certain areas or borders of
the base thus changing its extension.
OUTLINE
POLISHING
Over heating
 As the brushes and pumice are used to gain the final
luster of the polished surface of the acrylic resin, a rise
in temperature takes place due to friction.
 Careless technician may ignore over heating thus
leading to warpage of the denture base.
 This error is avoided by cooling the base in water
during polishing.
THANK YOU

Failures of RPD

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Failures of RPD

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FAILURES OF REMOVABLE

Polykarpos Memy Mahrous

 For the construction of an accurate RPD that

 So, to understand the ERRORS that may lead

 Ideally, a special tray should provide

 Errors resulting and their possible treatment

 This change in path of insertion changes:

A. Selecting a defective path of insertion

 If the technician proceeded with the defective

B. Desirable undercuts errors

▪ Also the technician may choose a clasp that is not

B. Desirable undercuts errors

▪ Such errors may vary from:

D. Errors related to relief

D. Errors related to relief

A. Using expired agar

A. Using expired agar

B. Not cool enough agar error

Careless wax pattern

▪ Unfortunately, errors of under waxing in

Warpage of framework may occurs due to:

- In such a case, the affected clasp may be cut

Errors resulting and their possible treatment

A. Far labial arrangement

B. Posteriors out of the crest

Errors resulting and their possible treatment:

B. Bleaching of the acrylic resin

C. Separation of teeth from the base

Breakage of teeth and/or denture base

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