Old denture base materials

• Wood, Bone, Ivory

• Gold, Porcelain
• Celluloid, Vulcanite,
• Bakalite , Stst
Metallic Denture bases
• Gold
• Stst
• Co-Cr, Ni-Cr
• Titanium
PMMA , improvements
• Filler, fibers

Thermoplastic resins
Thermoplastic acrylic resin,
Polyamide
Polyoxymethylene, Polycarbonate
PEEK
 Denture Base Materials

The part of a denture that rests on the foundation tissues and to which
teeth are attached (GPT 9) 

Old denture base materials:

• The first dental prosthesis was believed to have been constructed in
Egypt about 2500 BC.
• Skillfully designed dentures were made as early as 700 BC using
ivory and bone. Till 1800s, dentures were hand carved and tied in
place with silk threads.
 Ideal requirements of a denture base material:

1.Biological:
tasteless, odorless, nontoxic, nonirritating, impermeable to oral fluids and discourage
bacterial growth.
2.Physical:
adequate resilience, good dimensional stability and resistance to thermal changes, low
density
3. Mechanical properties: adequate strength ,High abrasion resistance. High flexure and
impact strength
4. Esthetics: exhibit sufficient translucency, accede pigmentation and show no color
change over time.
5. Handling: Should not produce toxic fumes, easy to mix, shape and cure, easy to polish
and repair.
6. Economic: cost of the material and processing should be practical and feasible
other Prop: Radio-opacity. Good adhesion with denture teeth and liners
 Metallic:
Gold, its alloy, Al, Co-Cr, Ni-
Cr, Titanium
Based on material
Non-metallic:
DENTURE BASE Acrylic resin ,poly amides,
MATERIALS polyoxymethylene, PEAK
Temporary:
shellac, base plate wax, cold
Based on durability cure acrylic

: Permenant
Gold, CoCr alloy, Heat cured
acrylic resin, filled PEEK
Classification of denture base material according to material:

Metallic denture Non-metallic

base denture base
• Gold Alloy • PMMA
• Stainless steel • Polyamides
• Cobalt chrome, • Polyoxymethylene
Ni-Cr
• Peak
• Titanium alloy
 A- Metallic Denture Base
Gold alloy (type IV)
In 1794 AD, John Greenwood began to swage gold bases for dentures.
Usually 18 to 20 carat gold was alloyed with silver and teeth were riveted to it.
-Less rigid than chrome cobalt, but more rigid than resin.
-More heavy than cobalt chromium ,so it can be used in lower dentures to
increase the retention.

Stainless Steel (Fe-C-Cr)

When approximately 12% to 30% chromium is added to iron ,the alloy is
called STAINLESS-STEEL.
-Used in Swaged form
-Less commonly Used as it less acurrate than gold and chromcobalt
 Cobalt-chromium alloy
At 1939 Nearly all partial denture were fabricated by cobalt-chromium alloy.
- less ductile than Ni-Cr.
- not used for metal ceramic prostheses, (oxide layer formed are susceptible to
delamination and adversely affect the bonding with porcelain)
Advantages:
• Has High tarnish resistance
• High polishing
• High strength
composition :
Principle elements (approx. 90%).
Cobalt 60%.
Chromium 25% to 30%.
Mo, silicone, Al, nitrogen Berylium, carbon, Mn
Chrome: Responsible for the tarnish resistance and stainless properties. (if >30% it is more
difficult to cast)
Cobalt increases the elastic modulus ,strength and hardness more than Nickel does.
Other components :
1-Carbon:Increase in carbon content increases the hardness of Co-based alloys.
1-Molybdenum : Contributes to the strength of the alloy.
2-Aluminium: Forms a compound with Ni and Al (Ni3Al) which increases the tensile and the
yield strength of the alloy.
3- Berylium : About 1% lowers the fusion temperature range of the alloy by about 100
degrees.
4- Silicone and manganese: increase the fluidity and castability of these alloys.
5- Nitrogen: If present contributes to the brittle qualities of these alloys.
 Nickel-chromium alloy
Composition :
Most common base metal alloy in metal ceramic restorations
Nickel is combined with chromium to form a highly corrosion resistant alloy
• Nickel (61.5-77.5%).
• Chromium (12.8-22%).
• Mo (4-14%)
• Al (0-4%)
• Iron (0-5%)
• Ni-Cr-Be (0-2% Be)
 Titanium alloys

Advantages:
• light weight, adequate strength, good corrosion resistance, excellent
biocompatibility
• used as dental implants, implant prosthesis, cast partial dentures and
metal ceramic prostheses
• Highest melting point of all metals and alloys used in dentistry (upto
1668°C) difficult to cast, requires a special casting machine.
- Titanium forms porous and non-adherent oxide layer which does not
form reliable porcelain to metal bond.
• Their main disadvantage is cost.
• The use of titanium is ideal in patients who report a history of
allergies to conventional metal alloys
 Fabrication Of Metallic Denture
Base Done By 2 Ways :

1-Lost Wax Technique

2- CAD/CAM System
A-Additive Manifacturing Technique (3DPrinting)

Materials Used For 3D Printing

1-Resin Like PLA , Nylon and Epoxy resins
2- Metal like Silver, Steel and Titanium
3-Organic like Cells

Mechanisms of 3D Printing
1- Fused deposition modeling
2-Selective Laser Sintering
3-Stereolithography
B- Subtractive Manufacturing Technique:
• Subtractive production methods include grinding a block using special types of burs
made from zirconium or steel.
• But one of the most disadvantage of this technique is the fracture and the abrasion of
the burs and they are very expensive.
• Titanium Blocks Can Be Used
Shape of Method of Mechanism
Material printing
Filament Heat Fused deposition
modeling
Powder Laser Selective laser
sintering
Liquid UV laser Stereolithography
B- Non-Metallic Denture Base :-

Polymethylmethacrylate
(PMMA)

Polyamides (Nylon)

Polyoxymethylene

PEAK
 Polymethylmethacrylate (PMMA)
Introduced in dental application in 1936 by Dr. Wright and Vernon brothers

ADVANTAGES:
1. It has good stable color which can
be made to correspond to either
gingiva or the teeth
2. Chemically bond to teeth (made of
PMMA)
3. Ease of processing & repair.
4. Cost efficient
DISADVANTAGES:
1. Residual monomer allergy
2. Poor mechanical strength
3. Low fatigue strength
4. Poor conductor of heat
5. High coefficient of thermal expansion
6. Polymerisation and thermal shrinkage

to overcome these drawbacks search for newer materials begun

PMMA
 1-Heat Cured PMMA
Since the mid-1940s, the majority of denture bases have been fabricated using PMMA resins.
Composition :
1-Liquid:
- MMA
- Inhibitors(hydroquinone) to prevent polymerization of the monomer during storage.
-Plasticizers to produce soft and more resilient polymer.
2- Powder:
-Granules of Polymethyl methacrylate Polymer.
-Initiator(benzoyl peroxide).
-Plasticizer.
-Pigments.
 stiff
Rubbery
Dough like

Stringy

Sandy
 A-Compression Molding
Technique

The molding material is first placed in

an open mold cavity. The mold is
closed with a top force or plug
member, pressure is applied to force
the material into contact with all mold
areas, while heat and pressure are
maintained until the molding material
has cured.
 B-Injection Molding
Technique
• Half the flask is filled with stone
• Contoured and permitted to set
• Sprues are attached to the wax
denture base
• Investment process is completed
• Wax elimination is performed
• Flask is placed under pressure
• Eresin matrix is introduced into the
mold and polymerized
Curing of Heat cure PMMA

1. Long Cycle: constant temperature water bath at 74°C for 8 hours or

longer without terminal boil
2. 74°C for 8 hours or longer followed by a terminal boil at 100°C for
1 hour.
3. Shorter cycle: At 74°C for approximately 2 hours then boiling at
100°C for 1 hour or more.
Chemically Curing PMMA
-This resin is similar to Heat accelerated Polymer.
-The Main Difference is that the polymerization reaction is accelerated by
chemicals such as Dimethyl-P-Toluidine.
-Chemical Cured Resin has Inferior Mechanical prosperities than heat cured
acrylic resin so it can be used in :Repair denture Base, Special Tray, Trial
Denture base

Pour Type Denture Resins(Fluid-Resins)

-The same chemical composition as Self-Cure PMMA
- The Principle difference in the size of the polymer's beads (Much Smaller,
Produce Very Fluidy Mix)
- Injection molding technique is used to inject the mix into the mold.
High-Impact Strength Resins
- They are Similar To The Heat Cured PMMA , They reinforced by
rubber Particles.
- The rubber particles are grafted to MMA
- They supplied in Powder and liquid form
-They have high impact strength so they will stop the crack
growth showing High degree of resistance to fracture, indicated for
patients who drop their dentures repeatedly e.g. parkinsonism, senility
Light Activated Resins
-High Molecular Weight Resins.
-Present as Single Component System (Pre-mixed Sheet) Which is
adapted to the cast then polymerized In a light Chamber (Curing Unit).
Can be used as custom tray.
-Very Expensive, There is no improvement in Physical Properities than
the other types.
Gel-Type Acrylic Resins:
-It has the same composition as the powder and liquid type used for heat
cured acrylic resin, except that they are supplied in the form of sheets of
a gel structure.
-they are moulded into the required shapes then the polymerization is
initiated by application of heat.

Microwave Activated PMMA :(Nishii, 1968)

-Using Special Formulated Resin and Non-Metallic Flasks.
-Using The Conventional Microwave To Supply The Thermal Energy
and Electromagnetic Waves.
-Due To Faster Penetration Of the Resin :- There is homogenous Curing
and Excellent details.
 Properties of PMMA
Physical properties
Melting point = 48o C
Boiling point=100.8o C
Density=0.945g/mL at 20o C
Heat of polymerization=12.9
Kcal/mol
Volumetric shrinkage= 21%
Mechanical Properties
Hardness number =18 to 20
Tensile strength = 55 Mpa
Compressive strength = 76 Mpa
Density =1.19 g/cm cube.
Modulus of elasticity = 3800
Mpa
Proportional limit is 26MPa
Drawbacks:

• Low Strength (adequate for Rp application)

• Low Hardness (can be scratched , abraded)
• Low impact strength (addition of plastizier)
• Polymerization shrinkage (21% – prepolymerized beads)
• Denture Warpage (stress- packing in rubbery-improper flasking)
• Porosity (compromise physical, esthetic, hygienic properties of
denture)
• Water Sorption (acts as plasticizers, causes slight expansion )
• Crazing (cracks due to stress relaxation)
• Plaque Adhesion (esp. rough surfaces)
• Cytotoxity: (Autoploymerized resins : most cytotoxic denture base
material. microwave cured types are less cytotoxic. Water storage
may reduce the level of residual monomer, resulting in decreased
cytotoxicity).
 Porosity

cause manifestation Defect

Inadequate pressure or insufficient Porosity throughout the denture, denture Contraction porosity
material may be in correct in shape
Vaporization of monomer during Porosity in localized area esp. thick parts. Gaseous porosity
processing Each defect is sharply defined and round

Incorrect polymer: monomer ratio In thin sections, white and frosty Granular porosity
when producing the dough or failing appearance
.to pack the flask at the dough stage
 Attempts to improve the mechanical, Physical properties of
PMMA

1. Reinforced resins
• High impact resins
• Fiber-reinforced
2. Hypoallergenic resins
3. Resins with modified chemical structure
4. Thermoplastic resins
5. Enigma gum toning in denture bases
Attempts to improve the mechanical, Physical properties of
PMMA
• Reinforced resins (High impact resins Fiber-
1 reinforced )

2 Resins with modified chemical structure

3 Thermoplastic resins

• 4 Hypoallergenic resins

5 Enigma gum toning

 Reinforced resins

Fiber-reinforced resins:
• Primary problem with PMMA is low impact strength & low fatigue
resistance. 68% dentures fracture within few years of fabrication.
• Maxillary fractures are caused by a combination of fatigue (under
occlusal forces) & impact whereas 80% of mandibular fractures are
caused by impact.
• Fiber reinforcement result in a 1000% strength increase over non-
reinforced
 Fiber-reinforced Resins
 Glass, carbon/graphite, aramid and ultrahigh molecular weight
polyethylene have been used as fiber reinforcing agents.
 Metal wires like graphite has minimal esthetic qualities.
 Fibers are stronger than matrix polymer thus their inclusion
strengthens the composite structure.
 The reinforcing agent can be in the form of unidirectional, straight
fiber or multidirectional weaves.
 Fiber-reinforced Resins
1- Metal reinforcement:
provides best reinforcements, not widely used unesthetic, expensive, poor bonding with acrylic (pmma),
corrosion prone

2-Carbon/graphite fiber reinforcement

placed during packing. provides greatest reinforcement of denture base resin in terms of flexural
strength. Carbon Graphite fibres are available as (chopped, continuous, woven, braided & tubular)
Disadvantages:
• Unesthetic because of black colour, can be covered by an opaquer.
• The polishing is difficult & weakens the finished prosthesis.
• there is problem of lateral spreading of fibers during pressing.
 Fiber-reinforced Resins
3- Aramid fiber reinforced
increases the strength but unesthetic & difficult to polish so limited
to locations where aesthetics is not important.

4- Polyethylene fiber reinforced

Multifibered polyethylene strands are placed in resin during packing. They develop
anisotropic properties to the composite (i.e. increase strength and stiffness in one direction),
Another biggest advantage is their esthetics (almost invisible). Placement & finishing is
difficult as fibers tends to protrude outside mould.
Highly drawn linear polyethylene fibers (HDLPF)
Patterns of continuous parallel fibers provide maximum reinforcement to both maxillary &
mandibular bases. HDLPF Have high tensile stiffness & strength, notch insensitivity &
cracks do not propagate through array of fibers. The coherence is maintained even after a
large number of testing cycles.
 Fiber-reinforced Resins
5- Glass fibres (have best aesthetics) :
Continuous parallel fibers provide high strength & stiffness in one direction
(anisotropic) while randomly oriented fibers provide similar properties in all directions
(isotropic properties). Six mm chopped glass fibers with 5% fiber in combination with
injection moulding technique result in increase in transverse strength, elastic modulus&
impact strength. Glass fibers may be modified by plasma polymerization technique
using HEMA, EDA, TEGDME.
ADVANTAGES
These are the fibers of choice because of well documented improvement in flexural
properties and fatigue resistance & the best aesthetics & excellent polishing
characterstics, they resist extreme temperature, moisture, oil.
 Fiber-reinforced Resins
E-GLASS FIBERS:
Each strand of this E-glass is computer impregnated with a PMMA (porous
polymer) and silane coupler that allows dissoloution bonding to acrylic. (e.g.
Preat Perma Fiber) Available in two forms (mesh & fiber), are transluscent
providing esthetics, have more strength.
comparison of impact strength of resins reinforced with different fibers:
Polyethylene > glass > thick Kevlar >carbon >thin Kevlar > unreinforced.
 Resins with modified chemical structure

• Addition of hydroxy-apatite fillers increases fracture toughness.

• Addition of Al2O3 fillers increases the flexural strength & thermal diffusivity
that could lead to more patient satisfaction
• Addition of ceramic or sapphire whiskers to improve thermal diffusivity
• Addition of Triphenyl Bismuth (Ph3Bi) new additive to provide radiopacity.
• Addition of silver Nano particals (AgNPs), improve thermal conductivity and
compressive strength, prevent denture stomatitis, recurrent allergic and
microbial infection, enhance the ability to sense temperature changes of
food and that relief complaint of menopausal symptoms
• Zirconium oxide nanoparticles are usually used to reinforce polymers and
improve the strength of the reinforced PMMA matrix
 Hypoallergenic resins
• Due to residual monomer that result after polymerization of the resin :
• sometimes there is allergic reaction present under the denture in the palate
or oral mucosa in form of: burning sensation contact dermatities
• Diurethane dimethacrylate, polyurethane, polyethylenterephthalate and
polybutylentereph-thalate. Hypoallergenic denture base materials exhibit
significantly lower residual monomer content than PMMA
• Inhibition of candida albicans –preventing denture stomatitis PMMA –
silver nanoparticle discs were formulated with the commercial acrylic resin
 Rapid Heat Polymerized Polymer
• These are hybrid acrylics which have had the initiator
formulated to allow for very rapid polymerization without
porosity.
• The flasks are placed in boiling water immediately after
being packed. The water is then brought back to a boil for 20
min to complete the curing cycle.
• Fast, high temperature cure makes this material stiffer than
conventional acrylic processing
 Thermoplastic resins

1- 2- 3- 4- 5-
polyamides polycarbonat Thermoplastic Polypropylene Polyoxymethylene
(nylons) e, polyester acrylic resins (Acetal resins)
resins

c
 Thermoplastic resins
• The use of thermoplastic resins in dental medicine is continuously
growing.
• The material is thermally plasticized, and no chemical reaction takes
place.
• The injection of plasticized resins into a mold
• At present, due to successive alterations in the chemical composition,
thermoplastic materials are suitable for manufacturing RPD with no
metallic components, resulting in the so-called “metal-free removable
partial dentures
 Thermoplastic Resin

Indications for thermoplastic resins include

1- Removable partial dentures.
Figure 17

2- preformed clasps.
3- partial denture frameworks
4- anti-snoring devices, different types of mouth
guards and splints,
5- provisional crowns and bridges.
 Thermoplastic resins

Advantages of thermoplastic materials :

• Excellent esthetics (tooth or tissue colored), very comfortable for the

patient.
• These are very stable,
• have high fatigue endurance, high creep resistance, excellent wear
characteristics & solvent resistance.
• They are non-porous so no growth of bacteria,
• They are unbreakable, flexible, light weight.
 1- Thermoplastic polyamide (nylon)
• Thermoplastic polyamide (nylon) is a resin derived from
diamine and dibasic acid monomers.
• First introduced in 1956
• Nylon exhibits high flexibility, physical strength, heat and
chemical resistance.
• It can be easily modified to increase stiffness and wear
resistance.
Nylon is mainly used for:
1-Flexible partial Denture
2-Tissue supported removable dentures.
3-Its stiffness makes it unsuitable for usage as occlusal rests or
denture elements that need to be rigid .
4-Because it is flexible, it cannot maintain vertical dimension
when used in direct occlusal forces.
5- Acrylic teeth do not bond chemically with flexible denture base.
 VALPLAST

Valplast is a pressure-injected, flexible denture

base resin that is ideal for partial dentures and
unilateral restorations.
The resin is a biocompatible nylon thermoplastic
with unique physical and esthetic properties.
THE BENEFITS OF VALPLAST :
1-Natural Esthetics
2-Patient Comfort:
3-Durable:
4-Biocompatible:
5-stress-breaker
Comparison Between Conventional Dentures and Nylon Dentures.
Conventional Denture Nylon Denture

Rigid : Difficult to Be used in Undercut Flexible

areas
Brittle : Fracture Easily Have High Fracture Resistance

Less Esthetic ( Metal Clasps) More Esthetic (The Same Gingival

Colour)
Residual Monomer (Allergic Reaction) Monomer Free

Hard denture Low Hardness

Teeth Bond to denture base chemically Mechanical Bonding of the teeth to the
denture base
 2-Thermoplastic acrylic:

• Heat-cure polymethyl methacrylate demonstrates (high porosity, high

water absorption, volumetric changes and residual monomer).
• Thermoplastic acrylic has poor impact resistance, but has adequate
tensile and flexural strength, providing excellent esthetics.
• The material is easy to adjust, handle and polish. It is relineable and
repairable at the chair-side
• Flexite M.P.-a thermoplastic acrylic, is a special blend of polymers and
has the highest impact rating of any acrylic & does not crack even if
falls on floor, thus very popular for bruxism appliances as well as
dentures.
 3- Polycarbonates
• Polycarbonate is a polymer chain of bisphenol-A carbonate.
• polycarbonate resin is also very strong, resists fracturing, and is quite
flexible.
• Polycarbonate is not suitable for full or partial dentures but ideal for
provisional crown & bridges.
• The material has a natural translucency and finishes very well, yielding
excellent esthetics.
• Temporary and provisional restorations with thermoplastic polycarbonate
provide patients with excellent short or mid-term function and esthetics.
 Polycarbonates
• ADVANTAGES
• It doesn’t use monomer, catalyst, physical properties become stable without
deteriorating.
• little water absorption so no bad smell by saliva absorption & safe to use (no
stimulation to oral mucous membrane or redness).
• Adherence and coherence degree is good as it has superior affinity with mucous
membrane.
• superior in impact proof, stress cracking and abrasion proof.
• DISADVANTAGES
• Elaborate processing equipment & high moulding temperatures with greater
distortion from water sorption, high flexibility, low hardness and low adhesion
to acrylic teeth.
 3-Poly oxy-methylene (acetal-resin)
-Thermoplastic acetal is a poly(oxy-methylene)-based material.
- first proposed as as an unbreakable thermoplastic resin RPD material
in 1971,
- The acetal resin has optimal physical and chemical properties.
- Used in denture base due to its resistance to wear and fracture,
combined with a certain amount of flexibility.
Uses:-
1-Clasps for partial dentures.
2-single-pressed unilateral partial dentures.
3-partial denture frameworks.
4-occlusal splints, Overlay prosthesis, bite raising ,snap on prothesis
(Hollywood smile)
5-implant abutments.
6- Long term provisional bridges,
7- Come in crystals for injection ,in blocks for CADCAM
• Experimentally, in some cases, we combined an acetal resin frames with classic
acrylic resins for the saddles .
• However, the resistance values for the acetal resin framework do not reach those
of a metal one
• consequently the main connector, the clasps and the spurs need to be oversized.
• Thermoplastic acetal comes in 18 Vita shades + 3 pink shades to match most
people’s teeth or gums and clasps are tooth coloured clasps (made of acetal resin)
so provide good esthetics
Resin clasps engage the first third (or origin) of the undercut
rather than the terminal third as in metal clasps allowing three
to four times the retention of metal. The clasp can then be
placed more gingival increasing its aesthetic appeal beyond the
obvious colored properties
no need for adjusting is usually not necessary or recommended
as the clasp is injected to the tooth contour and is permanent.
 PEAK (Polyrtheraryl ketone)
Carbon-
filled
Unfilled
Ceramic
PEEK fiiled
PEAK Filled
PEKK
Glass fiber
)Pekkton(

Nanofilled
 Poly Ether Ether Ketone (PEEK)
 
PEEK is a semi-crystalline thermoplastic with excellent mechanical- and
chemical-resistance properties that are retained even at very high temperatures.
-Because of its toughness, this material is used in the field of prosthetic dentistry.
-Be it a permanent, removable or a screw-retained prosthesis that is
required, PEEK is an innovative, premium prosthetic solution in the field of
dentistry.
 Advantages of BioHPP material
• The major beneficial property that makes it comparable to titanium,
Zirconium, PMMA is the elasticity of the material which very
strongly resembles the elastic range of bone, makes it a more natural
material, encourage bone remodeling,
• low specific mass, toughness, and non-existing material fatigue
make the material ideal partner in prosthodontic dentistry and
implantology
• Also it can be considered as an alternative to precious metals and
ceramic restorations as it can be easily and highly polished; it does
not cause abrasion to antagonist; it protects natural teeth.
• Resistant up to 1200 N due to the low elastic modulus
• high wearing comfort for the patient due to their low density
• Can be manufactured using (compression technique, CADCAM)
 Application of PEEK in dentistry
The improvement with ceramic fillers enabled the material to have
significantly improved (strength, abrasive properties, ability to be
veneered) and has therefore been adjusted to suit the requirements
and uses in dental medicine as :
PEEK Application:
1. RPD framework (unfilled PEEK)……
2. Precision attachment (the PEEK frame acts as the matrix itself while the patrix is
incorporated at the distal ending of the fixed crowns and bridges.)
3. Fixed partial denture: (unbreakable, replace metal ,zirconium in long span)
4. Implnt abutments &framework .
• Temporary (unfilled)
• permenant (BioHPP on ti base)
5. Telescopic restorations
6. Subperiosteal implant
7. Maxillofacial reconstruction (cranial , zygoma, condyle)
8. Implant ( under research)
 Advantages of PEEK RPD:
• High biocompatibility
• Good mechanical properties
• High temperature resistance
• Chemical stability
• electrically non-conductive
• Due to a 4 GPa modulus of elasticity, it is as elastic as bone and can
reduce stresses transferred to the abutment teeth

Disadvantages of metallic RPD :

• Esthetically unacceptable display of metal clasps
• Increased weight of the prosthesis,
• Potential for metallic taste
• Allergic reactions to metals
 NOTE

These properties of PEEK prevent any intra-oral reaction to saliva making it an

ideal material for use within the oral cavity
PEEK RPD can be manufactured by

1. Conventional lost wax technique .

2. CAD-CAM Systems By Subtraction Technique Using PEEK Block.