MODEL AND DIE MATERIALS

DEFINITIONS
 Impression: negative replica of hard and soft oral
structures.

 Cast or Model: positive replica of hard and soft oral

structures and used for the construction of dental
appliances.
 DEFINITIONS
 It is formed by pouring the impression by one of the
model materials.

 Die: it is a model for single tooth.

 It is a positive replica of the individual prepared
tooth on which the inlays and crowns are made.
 Types of model and die materials
Non-metallic casts and dies Metallic dies

A. Gypsum model and dies A. Electroplated dies

i. Type II Model plaster B. Amalgam die
ii. Type III Hard stone C. Low fusing metal dies
iii. Type IV Extra hard stone
iv. Type V Extra hard, high
expansion stone
B. Polymer
i.Acrylic
ii.Epoxy
C. Cement
i.Silicophosphate cement
D. Ceramics
• Ideal requirements of model and die materials
1.It should be dimensionally accurate.
2.It should have high abrasion resistance to resist
scratching during carving of wax pattern.
3.It should possess good strength and have
smooth surface.
4.Ability to reproduce all fine details in the
impression.
5. Compatibility with all impression materials.
6. Color contrast with wax pattern for easy
differentiation.
7. Easy & quick manipulation.
8. Non-injurious to health by touch or inhalation.
9. Economic.
10. It should have reasonable setting time.
 Non-metallic casts and dies
A. Gypsum model and dies
Note:
•Type I is used as impression material, while the
other four products (II, III, IV, and V) are
laboratory materials and used for model and die
construction.
•All these products are derived from raw gypsum
material (CaSO4.2H2O).
• When it is ground and heated up (to change it
into a powder), it loses water and becomes
hemihydrates of calcium sulfate (CaSO4.1/2H2O).
CaSO4.2H2O Heat CaSO4.1/2H2O + 1.5H2O
Dihydrate Calcination Hemihydrate

Calcination Reaction
• Gypsum products are chemically the same
(CaSO4.1/2 H2O) but they differ in:

1. Method of manufacturing.
2. Particle size and shape.
3. Water/powder ratio.
4. Physical and mechanical properties.
5. Uses.
 Characteristics of different gypsum products
Difference Model Plaster Hard stone Extra hard Extra hard, high
(Type II) (Type III, stone expansion stone
Hydrocal) (Type IV, (Type V)
Densite)
1. Source CaSO4.2H2O CaSO4.2H2O CaSO4.2H2O CaSO4.2H2O
2.Manufacturing Heating of Autoclaving of Boiling of Same as Type IV,
CaSO4.2H2O at CaSO4.2H2O CaSO4.2H2O in but decrease the
120°C in open at 120°-130°C 30% CaCl2 or percentage of
air (α- MgCl2 antiexpansion
(ß- hemihydrate) (α- additives (α-
hemihydrate) hemihydrate) hemihydrate)

3. Particles (size & CaSO4.1/2H2O CaSO4.1/2H2O CaSO4.1/2H2O CaSO4.1/2H2O

shape) Large, irregular, Smaller, more Smallest, most Smallest, most
& porous regular, & less regular, & least regular, & least
porous porous porous
4. P/L ratio 100 g/50 ml 100 g/35 ml 100 g/22 ml 100 g/20 ml
 Characteristics of different gypsum products

Difference Model Plaster Hard stone Extra hard Extra hard, high
(Type II) (Type III, stone expansion stone
Hydrocal) (Type IV, (Type V)
Densite)

5. Excess water Largest Large amount Least amount Least amount

amount
6. Compressive Low Moderate High High
strength
7. Abrasion Low Moderate High High
resistance
8. Porosity High Moderate Low Low
9. Setting High Moderate Low High
expansion
 Characteristics of different gypsum products
Difference Model Plaster Hard stone Extra hard Extra hard, high
(Type II) (Type III, stone expansion stone
Hydrocal) (Type IV, (Type V)
Densite)

10. Uses 1. Diagnostic 1. Full or partial • Used for • Used for

cast. denture master making cast construction of
2. Articulation of casts. and dies for dies on which
stone cast. inlay & crown base metal alloys
2.Orthodontic fabrication. will be casted with
models. increasing setting
expansion to
3. Flasking compensate for
procedure for alloy solidification
acrylic dentures. shrinkage.

3. Flasking
procedure for
acrylic dentures.
Setting reaction:

CaSO4.1/2H2O + 1.5H2O CaSO4.2H2O + Heat

• The chemical reaction called crystallization in

which the calcium sulphate hemihydrate
particles change into calcium sulphate
dihydrate crystals. This an exothermic
reaction.
• Mechanism of reaction:

A.Solubility:
Hemihydrate particles dissolve in water to form
a super saturated solution of dihydrate.
B.Precipitation:
When solution reach its saturation stage. The
precipitation of small dihydrate crystal is formed
and they are called nuclei of crystallization.
C. Crystal growth:
Continuing precipitation around nuclei
growth of the formed crystals.
D. Intermeshing and setting:
Growth of the crystals will lead to intermeshing
and this will change material from soft state to be
coherent and hard mass.
Manipulation
1. Powder is shifted into water in the mixing bowl to
ensure good wetting and avoid air bubbles.
2. Metal spatula is used for hand mixing for 1 minute,
against the wall of the rubber bowl.
3. Mechanical mixing can be done under vacuum to
reduce the entrapped air.
4. Vibration is done immediately after mixing and during
pouring minimizes air bubbles in the set mass.
5. The mix is made to flow on the surface of the
impression.
Rubber bowl
& spatula
A Vibrator is designed to
promote the release of
bubbles in the gypsum mix

Power-driven mechanical
spatulator with a vacuum
attachment
6. The gypsum material is allowed to set for 45 to 60
minutes.
7. After separation, the model should be disinfected.
Notes
• Initial setting time: Time elapsed from the start of mix
until loss of gloss (8-10 minutes).
• Final setting time: The time at which the material can
be separated from the impression without distortion
or fracture. The gypsum is cool (exothermic reaction
is over).
• Setting expansion: Results from crystal growth
of dihydrates during setting.
• Hygroscopic expansion: If gypsum is soaked in
water during setting, water fills the pores
leading to additional crystal growth. It is
double the setting expansion.
• Strength increases 2-3 times after 24 hours.
Factors affecting setting time
1. W/P ratio
• Increasing water ratio will lead to presence of
large spaces between the growing crystals and
so they take longer time to set.

 
2. Spatulation
• Rapid and prolonged spatulation accelerates the
setting reaction as higher number of nuclei of
crystallization are formed.
3. Temperature
• Increasing water temperature to a certain level
will accelerate setting reaction.
4. Impurities
• Impurities will accelerate the setting reaction by
providing nuclei of crystallization.
5. Fineness
• The smaller the particle size, the faster the mix
will set by increasing nuclei of crystallization.

6. Accelerators and retarders

Accelerators
• The substances which decreases the setting time
of gypsum products by increasing the rate of
reaction are called accelerator. E.G. potassium
sulfate
 Retarders
• They are the substances which increases the setting time
of gypsum products by decreasing the rate of reaction.
E.G. Borax.

 Infection control
• Casts should have set for 24 hours before being
disinfected if necessary.
• Spray rather than immerse.
• Disinfectants commonly used:
1. Sodium hypochlorite 2. Iodophors 3. Chlorine dioxide
• Advantages of Gypsum as a model and die
materials
1. Inexpensive and easy to use.
2. The accuracy and dimensional stability are
good.
3. Reproduction of fine detail from the
impression.
• Disadvantages
1. Susceptibility to abrasion during carving of the
wax pattern (low abrasion resistance).
 B. Polymer dies
1. Acrylic resin dies
• Self curing acrylic resin with fillers can be used
for die construction.
• Advantages
 More abrasion resistance than stone dies.
• Disadvantages
 Polymerization shrinkage.
2. Epoxy die materials
• The material is a two component system:
1. Paste containing the resin.
2. Liquid hardener or activator.

Advantages
1. The materials show more resistance to abrasion
and are stronger than a high strength dental
stone.
• Disadvantages
1. They do not reproduce the fine details as dental
stone because of the high viscosity of epoxy resin
paste.
2. They shrink by about 0.1% during hardening.
3. Expensive.
 C. Cement dies
• Silicophosphate cement may be used with all
impression materials.
• It is vibrated into impression and is ready for use
within an hour.
Advantages
• Harder than stone die.
Disadvantages
1. Brittle and fractured in thin sections (e.g.
interproximal area, see the arrow).
2. The material shows setting contraction.
 D. Ceramic dies
• A special type of ceramic material can be used for
the construction of the single die.
• It is supplied as a powder and liquid that are
mixed and fired.
• Advantages
1. Hard and strong die.
• Disadvantages
1. The material shows shrinkage on firing.
2. Expensive and sensitive fabrication technique.
 Metallic Dies
A. Electroplated dies
• Electroplating involves the deposition of a coat of
pure silver or copper on the impression.
• Types of electroplated dies
1. Copper plated die
2. Silver plated die
• Advantages
1. Hard metallic smooth surface.
2. Reproduce fine details.

• Disadvantages
1. Expensive.
2. Waste time and sensitive technique.
B. Amalgam dies

• This material is similar in composition to the

amalgam filling materials (Ag-Sn alloy mixed with

mercury to form a plastic mass which can be

condensed into the impression).

• Advantages
1. High surface hardness.
2. Reproduce fine details and sharp margins.
• Disadvantages
1. Its use is restricted to rigid impression material
(compound) to withstand the forces of
condensation.
2. They have long setting time (24 hrs. to reach
complete setting).
C. Low fusing metal dies
• These alloys have low melting temperature and
can be melted and poured immediately into the
impression. E.G Bismuth-tin alloy
• Advantages
1. Hard metallic smooth surface.
2. Reproduce fine details.
• Disadvantages
1. Expensive.
2. Waste time and sensitive technique.