MODEL,CAST AND

DIE MATERIALS

PRESENTED BY
DR LEKSHMY AR

1
 Introduction
Definitions
Requirements of cast or die materials
Classification of model, cast or die materials
Gypsum
 History
CONTENTS  Classification
 Production
 Calcination
 W/P ratio
 Manipulation
 Setting reaction
 Setting time
 Control and methods to measure setting time
 Setting expansion 2
Properties
Types
Caring of the cast
Disinfection of cast
Advantages
Disadvantages
Synthetic Gypsum
Special Gypsum
Modification
Metal
Metal sprayed dies
Electroformed
Amalgam
Polymers
 Metal or inorganic filled resins
 epoxy 3
 DENTAL CAST:- A life-size likeness of some
desired form; it is formed from a material poured
into a matrix or impression or from a CAM
printed replica

DIE:- The positive reproduction of the form of a

DEFINITION prepared tooth in any suitable substance

MODEL:- A facsimile used for display purposes;

a miniature representation of something; an
example for imitation or emulation

GPT-9
4
 Accurate
Must be free of voids
Dimensionally stable
Smooth and hard surface
Easy to use
REQUIREMENTS OF Strong and durable to withstand the subsequent
CAST/DIE manipulative procedures without fracture or
abrasion
Satisfactorily reproduce fine details
Setting expansion, contraction and dimensional
variations in response to temperature changes
should be minimum
Economical
5
  GYPSUM
Type I [ Impression Plaster]
Type II [Model Plaster]
Type III [Dental stone]
Type IV [Dental stone high strength]
CLASSIFICATION Type V [Dental stone high strength, high expansion]
OF MODEL,CAST AND DIE  METAL
MATERIAL
Sprayed
Electroplated
Amalgam
 RESINS
Metal or inorganic filled resins
Epoxy
 OTHERS 6
GYPSUM

7
 HISTORY
oMineral mined in various part of the world but it is also
produced as an industrial by-product.
oVarious crystalline forms of gypsum such as selenite and
alabaster exist in nature.
oGypsum products are supplied as fine hemihydrate
powders that are produced by heating ground gypsum
particles. After mixing with water, the mixture reverts
back to gypsum.
oUsed today for many applications including
construction,fertilizer,food additives, medical devices,
pharmaceuticals and dental applications..

8
 CLASSIFICATION OF GYPSUM
(ACCORDING TO ADA SPECIFICATION NO 25)

1 2 3 4 5
Type I Type II Type III Type IV Type V
Impression Model plaster Dental stone Dental stone Dental stone
plaster with high with high
strength and strength and
low expansion high expansion

9
 These materials are produced by
calcining calcium sulfate dihydrate
Calcination: It is a process of
PRODUCTI removing the water of crystallization
ON from the dihydrate.

10
 CALCINATION

110-130o C 130-200o C
Calcium sulfate Calcium sulfate 200-1000o C
hemihydrate Hexagonal Orthorhombic
dihydrate [Plaster/ Stone] anhydrite anhydrite
(Gypsum)

11
 SETTING REACTION

(CaSO4)2.H2O + 3H2O 2 CaSO4.2H2O +Unreacted(CaSO4)2.H2O + Heat

Calcium Calcium
sulfate sulfate
hemihydrate dihydrate

12
SETTING REACTION

Explained by three theories

 Colloidal theory
 Hydration theory
 Crystalline theory

13
 COLLIOIDAL THEORY-
 Mahaelis in 1893
Hemihydrate
When mixed with water hemihydrate H2O
enters into the colloidal state through a Hemihydrate sol
sol-gel mechanism. In the sol state ,
H2O
hemihydrate particles are hydrated to
form dihydrate, thereby entering into Dihydrate sol
an active state H2O
Dihydrate gel

14
 HYDRATION THEORY

Hemihydrate + water
Suggest that rehydrated plaster
particles unite through hydrogen
Rehydrated particle
bonding with sulfate groups to form
the set material
Hydrogen bonding

Set dihydrate

15
 Hemihydrate + water

CRYSTALLINE THEORY-
Henry Louis Le Chateleir 1887
Suspension of hemihydrate

DISSOLUTION-PRECIPITATION
THEORY Saturated solution of
Hemihydrate
• Most widely accepted
• Dissolution of hemihydrate particle
Dihydrate
in water followed by instant
recrystallization to the dihydrate
• Become possible because of the Supersaturated solution of
solubility of hemihydrate in water is dihydrate
four times greater than that of the
dihydrate near room temperature Dihydrate crystals precipitate
16
MANIPULATION
Water/Powder ratio
• Very important factor in deciding the physical and chemical properties of
the final product
• Water requirement of a product is affected by
1.Shape and compactness of crystals
2.Small amounts of surface active materials like gum Arabic plus
lime markedly reduce water requirement
3.Particle size distribution

17
WATER-POWDER RATIO
Type W/P ratio

Type I 0.40-0.75

Type II 0.45-0.50

Type III 0.28-0.30

Type IV 0.22-0.24

Type V 0.18-0.22

PHILLIPS’ SCIENCE OF DENTAL

MATERIALS 18
 Mixing Time (MT) Working Time (WT)
Mechanical mixing:-20-30 sec 3 min
Hand Spatulation:-1 min

Setting Time (ST)

Initial setting time:- 5-13

min
Final setting time:- 45 min

19
SETTING TIME
Type Setting time (min)
Type I 4 +/-1
Type II 12+/-4
Type III 12+/-4
Type IV 12+/-4
Type V 12+/-4

PHILLIPS’ SCIENCE OF DENTAL MATERIALS

12TH EDITION 20
METHODS TO MEASURE
SETTING TIME

 Loss of gloss test for initial set

 Exothermic reaction
 Initial Gillmore test for initial set
 Vicat test
 Gillmore test for final setting time

21
 LOSS OF
GLOSS TEST
As reaction proceeds the
gloss disappears from the
surface of plaster mix

22
Exothermic reaction

The temperature rise of the mass may also used for

measuring the setting time. The reaction is exothermic

23
 VICAT
PENETROMETER

It weighs 300gm and needle diameter is 1mm and 5cm

long.The time elapsing from the start of mixing till the
needle does not penetrate to the bottom of the plaster is the
setting time.

24
 Gillmore Apparatus

Large
Gilmore • Initial setting time : mix can resist
Needle
penetration by a Gillmore needle which has
a tip 2.12 mm in diameter and weighs
Small 113.4g
Gilmore
Needle
• Final setting time : The elapsed time at
which a Gillmore needle weighing 453.6g
Gillmore Needles and with a tip 1.06mm in diameter leaves
only a barely perceptible mark on the 25
 Theoretically there are at least 3 methods can
achieve such control :-

CONTROL 1. The solubility of the hemihydrates can

OF SETTING be increased or decreased.

TIME 2. The number of nuclei of

crystallization can be increased or decreased.
3. Setting time can be accelerated or
retarded by increasing or decreasing the rate of
crystal growth.

26
FACTORS AFFECTING SETTING
TIME
1. Manufacturing process
2. Mixing and spatulation
3. Water/Powder ratio
4. Temperature
5. Modifiers

27
Manufacturing Process

• If calcination is incomplete and excess gypsum

is left in the final product ,the resulting plaster
will set faster
• If soluble anhydrite is in excess, plaster will set
faster
• Finer the hemihydrate particle size , the faster
the set

28
EFFECT OF
WATER/POWDER
RATIO ON SETTING
TIME

More the water used for mixing , the fewer the nuclei per unit
volume. Thus setting time will be prolonged

29
EFFECT OF
SPATULATION ON
SETTING TIME

Within limits the longer and faster the plaster is mixed the
faster it will set because nuclei of crystallisation are broken
and well distributed within the mass

30
 Modifiers of controlling setting time

Retarders : chemical modifiers have been used extensively to increase

setting time of gypsum products..
Eg: Borax, sodium chloride(20%), sodium sulphate(high conc), glue,
agar, coagulated blood

Accelerators : chemical modifiers have been used to decrease setting

time of gypsum products
Eg : Potassium sulfate(>2%) , NaCl (2%) ,sodium sulfate (3-4%), slurry
water(gypsum <20%), tera alba

31
 SETTING EXPANSION
Regardless of the type of gypsum product ,an expansion of the mass can be
detected during the change from the hemihydrate to the dihydrate.
Normal setting expansion
oAs low as 0.06% linear to as high as 0.5%.
oUndesirable in impression plaster , dental plaster and stone as it will result
inaccurate cast or change in the occlusal relation if used for mounting
oIncreased setting expansion is desired in case of investment materials as it
help to compensate the shrinkage of the metal during casting.
32
Setting Expansion of plaster:- 0.2%-0.3%

Low to moderate strength dental stone:-0.15%-

0.25%

High strength dental stone:- 0.08-0.10%

High strength, high expansion dental stone:-0.10-

0.20%
33
CONTROL OF SETTING EXPANSION

Mixing time
W/P ratio
Modifiers

34
HYGROSCOPIC SETTING EXPANSION

When gypsum product is placed under water before the initial set
stage , a greater expansion is seen.
Physical phenomenon and is not caused by a chemical reaction.
Twice that of normal expansion because of additional crystal growth
when placed under water

35
Mahler DB, Ady AB; An explanation for the
hygroscopic setting expansion of dental gypsum
products . J Dent RES 39:378-379,1960
36
TYPE HYGROSCOPIC SETTING EXPANSION

Min Max

Type I 0.00 0.15

Type II 0.00 0.30

Type III 0.00 0.20

Type IV 0.00 0.10

Type V 0.10 0.30

PHILLIPS’ SCIENCE OF DENTAL MATERIALS

12TH EDITION 37
EFFECT OF W/P RATIO AND MIXING TIME
ON SETTING EXPANSION OF PLASTER OF
PARIS
W/P Mixing Setting
ratio Time(min) Expansion(%)
0.45 0.6 0.41
0.45 1.0 0.51
0.60 1.0 0.29
0.60 2.0 0.41
0.80 1.0 0.24

From Gibson CS, Johnson RN : J Soc Chem Ind 51:25T,1932

38
PROPERTIES
• Strength
• Compressive strength
• Tensile strength
• Surface hardness and abrasion resistance
• Reproduction of details

39
STRENGTH
WET
STRENGTH
• Strength when excess free water is present in gypsum

DRY
STRENGTH
• Strength when the excess free water is lost due to
evaporation.
• Two times greater than the wet strength
40
Compressive strength

Drying period(hours) Compressive

strength(Mpa)
2 9.6
4 11.7
8 11.7
16 13
24 23.3
48 23.3
72 23.3

41
TENSILE STRENGTH
Gypsum is a brittle material so tensile strength is low.
Model plaster - 2.3Mpa
Tensile strength of dental stone is twice than that of
plaster

42
SUMMARY OF EFFECT OF MANIPULATIVE VARIABLES ON
PROPERTIES OF GYPSUM PRODUCTS
Manipulative Setting time Consistency Setting Compressive
Variable Expansion strength
Increase W/P Increase Decrease Decrease Decrease
ratio
Increase rate of Decrease Decrease Increase No effect
spatulation

Increase Decrease Decrease Increase No effect

temperature of
mixing water
from 23oC-30oC
43
 TYPES OF GYPSUM PRODUCT
Type I
Impression plaster
Composed of Plaster of Paris, K2SO4, Borax, Coloring
and flavoring agents
Setting time 3to 5 mnts
Rarely used anymore
Primarily used as final impression (wash impression) in
the construction of complete dentures
Bite registration material 44
Type II

Model plaster/Dental plaster

Contains beta hemihydrate and modifiers
Now used principally to fill a flask in
denture construction
Mounting cast on articulator
Usually marketed in white colour
Relatively weak
Compressive strength -9 Mpa
Tensile strength – 0.6 Mpa
45
Type III

Dental stone/Class 1 stone/ Hydrocal

Yellow/blue /green
Preparing master cast and to make models
Alpha hemihydrate +2-3% coloring
matter+K2SO4(Activator)+Borax (Retarder)
Rockwell hardness is 82
1 hr compressive strength of 20.7 MPa

46
Type IV

Class 2 stone , Densite, die stone, Improved stone

Hardest and strongest variety of gypsum product
Used when high strength and surface hardness is
required
Used to prepare die for making inlays and crowns
Rockwell hardness is 92
 Pink in color

47
•Type V

•Dental stone high strength, high expansion

•Most recent gypsum product
•Higher compressive strength
•Setting expansion has been increased to 0.10%-0.30% and this limits
casting shrinkage in noble metal alloys
•Indicated when inadequate expansion is achieved during fabrication of cast
crowns
•Avoided in dies for inlays- tight fit due to expansion

48
 CARING OF THE CAST
• Storage of either set plaster or stone, if temperature raise in between
90˚C-110˚C (194˚F- 230˚F) shrinkage occurs, as the water of
crystallisation is removed and the dihydrate reverts to hemihydrate.

• Also it is not safe to store or heat a stone cast in air at a temperature

higher than 55˚C (130˚F) as it will result in contraction

49
 DISINFECTION OF GYPSUM
PRODUCTS

5% phenol
2% glutaraldehyde
Autoclave sterilization of casts has been suggested
Iodophor spray
Immersion in 1:10 dilution of sodium hypochlorite for 30 mins

50
Dimensional accuracy of seven die materials .
Brian J Kenyon et al ,Journal of prosthodontics 2005

The study concluded that Type IV resin impregnated dental stone and
copper plated dies are dimensionally more accurate that Type IV and V
conventional stone die materials

51
ADVANTAGES OF GYPSUM PRODUCTS

 Easy workability
 Economical
 Good reproducing ability
 Excellent color contrast
 Dimensionally accurate and stable

52
Disadvantages of gypsum products

The mechanical properties are not ideal

Brittle nature of gypsum occasionally leads to fracture,

particularly through the teeth, which form the weakest part of any
model

53
SPECIALIZED GYPSUM
PRODUCTS
Dental casting investment
Adding a refractory material like silica ,quarts or crystobalite to dental
plaster or stone permits it to withstand high temperature
To prepare refractory molds for casting dental alloy

Synthetic Gypsum
By-product during the manufacture of phosphoric acid. More expensive but
when the product is properly made, its properties are equal to, or exceed
those of, the latter.
54
Orthodontic stone

• Orthodontist prefers a white stone or plaster for study models.

• These products have a longer working time for pouring of multiple
models.

55
Resin modified stone
Eg:ResinRock,Whipmix corporations
• Synthetic resin + alpha gypsum
• Less brittle ,improved surface smoothness, increased resistance to
abrasion
• Compressive strength 79Mpa

Mounting Plaster
• Used for attaching the cast to the articulator
• Low setting expansion(for accuracy of mounting)
• Low strength (Easy separation from the cast)
• Fast setting time(3mint)
56
Fast setting stone
Setting time 2mints
Early high compressive strength
Allows separation of the cast from the impression in 5 mints
Eg: S nap stone
Other modifications
1.Incorporation of wetting agents (Lignosulfonates)
2.Balanced Stone
3.Chromatic Stone

57
METAL
Electroformed
Sprayed metals
Amalgam

58
 ELECTROFORMED
DIES
Electrodeposition on the impression gives a hard metallic surface
to the cast
Not used currently

59
Electroforming

 Electroplating/Electrodeposition
 A thin coating of metal is deposited on the impression, after
which a gypsum cast is poured
 Cast thus obtained will have a metallic surface layer
 Plating can be done for
- individual tooth impression
- full arch impression
 Plating is done on
- Compound impression
- Polysulfide impression
-Silicon impression
60
COMPONENTS OF AN ELECTROPLATING
APPARATUS

• Cathode : The impression to be coated is made the cathode

• Anode : The metal to be deposited ie, copper or silver
• Anode holder, cathode holder
• Electrolyte : The solution through which the electric current is
passed. Ions are deposited from anode to cathode
Eg: silver cyanide, copper sulphate
• Ammeter : Registers the current in milliamperes
• Plating tank : Made of glass or hard rubber with a well fitting
cover to prevent evaporation 61
 SILVER PLATED DIES
-Poly sulphide and silicone impression
materials can be silver plated (cathode)
-Composition of electroplating bath solution
Silver cyanide : 36gm
Potassium cyanide : 60 gm
Potassium carbonate : 45gm
Water (distilled) : 1000ml

-Electroplated for 10 hours using 5-10 mA/cm 2

of cathode surface
62
COPPER PLATED DIES
Used only with rigid impression compound
Cathode _Impression coated with graphite or copper
Anode- pure copper metal
Electrolyte – acidic solution of copper sulfate +alcohol /phenol
Copper sulphate : 200gm
Sulfuric acid : 30 ml
Phenol sulphonic acid : 2ml
Water : 1000 ml

63
Advantages
Moderately high strength
Adequate hardness
Excellent abrasion resistance
Dimensional accuracy
Better marginal definition
Not very expensive
Does not absorb water or oil

64
Disadvantages

• Difficult to trim
• Not compatible with all impression material
• Silver cyanide and acid in the solution produces hydrogen
cyanide (‘death chamber gas’)
• Color contrast not as good as die stone
• Adaptation of wax not as good ,Pattern tends to lift from
margins

65
ETAL SPRAYED DIES

Bismuth-Tin alloy is used

It melts at 138˚C and this is directly sprayed into the impression
with polysulfide rubber based impression material.
 Advantage is rapid.
Disadvantage is that the resultant die is soft with poor abrasion
resistance.

66
Amalgam dies
They are made by packing amalgam into impression made of
impression compound.

Advantages
 Dies made of amalgam exhibit superior strength resistance to
abrasion and reproduce fine details and sharp margins.

Disadvantage
 It can be packed only into a rigid impression like that of
impression compound
67
 Long setting time
After packing the impression with amalgam the die can be
removed after a minimum of 12 hours, by gently warming the
compound

68
RESINS

69
 ACRYLIC RESINS

o Introduced to dentistry in 1937

o Mainly used as denture base
o Used for making preclinical
models
o More viscous than stone – prone to
air entrapment
o Abrasion resistance better than
dental stone
o High compressive strength than
stone
o Polymerization shrinkage 0.02%
70
EPOXY RESIN DIE MATERIAL
Most effective with rubber impression materials
Two components –Resin paste and hardener
Strength and abrasive resistance comparable to die stone
Disadvantage
Polymerization shrinkage 0.1- 0.2%
More prone to trap air
Less dimensional stability
Expensive
Prosthesis fabricated on resin dies tend to fit more tightly than those
made from gypsum
71
REFRACTORY DIES

Made from heat resistant material

Used in fabrication of large metal structures

Eg: cast removable partial denture

For making dies on which ceramic restorations are constructed

Eg: polyvest
Phosphate bonded die materials are most commonly used for the
construction of refractory dies
72
DIVESTMENT
Die stone-investment combination
 Combination of die material and investing medium
A gypsum- bonded material called divestment is mixed with a
colloidal silica liquid
A die is prepared from the mix and a wax pattern is constructed
on it
Then the wax pattern together with die is invested in divestment
Setting expansion : 0.9% , thermal expansion : 0.6% when
heated to 677˚C
Highly accurate technique for conventional gold alloys 73
FLEXIBLE DIE
Types:-
1. Polyether
2. Poly vinyl siloxane

74
POLYETH
ER oThe polyether cure through cross-
linking
oThe reaction involves ring opening
without formation of volatile byproducts
oPolyether is a stiff material so a thinner
is used to reduce the stiffness

75
COMPOSITION
Accelerator Paste
• Polyether polymer
• Colloidal silica - filler
• Glycoether or phthalate - plasticizer

Base Paste
• Alkyl-aromatic sulfonate
• Colloidal silica - filler
• Glycoether or phthalate - plasticizer

76
POLYVINYL
SILOXANE
Addition silicone
Introduced in 1970’s
Much greater dimensional stability
Less rigid than poly ether
Long term stability
Working time 1-4 min
Setting time 3-5 min

77
 COMPOSITION

Accelerator Paste/Catalyst Base Paste

•Divinyl poly siloxane • Poly methyl hydrogen siloxane
• Other siloxane prepolymers
•Other siloxane prepolymers • Fillers
•Platinum salts (Chloroplatinic acid)
•Palladium (hydrogen absorber)
•Fillers
•Retarders
78
Advantages

1. It is easy to fabricate
2. Chairside time is reduced
3. It is reusable unlike the stone casts.
4. Biocompatible
5. Good reproduction of surface details
6. Elastic in nature, thus reduces chances of distortion.

79
Disadvantages
1. Materials used to fabricate the cast are expensive.
2. At times, they adhere to the already set impression.

80
CERAMIC DIE MATERIAL

Ceramic slurry is mixed to a putty like consistency and packed into

the impression of the prepared tooth.
Then it is removed from impression and Fired at 600ᵒc for 8 mins to
produce strong hard die.
Used to fabricate die for porcelain inlays, onlays and veneers
Good abrasion resistance
Some shrinkage on firing

81
VIRTUAL CAST

82
TYPES OF OPTICAL IMPRESSION
AND MODEL TECHNOLOGY

CEREC
E4D
DCS PRECIDENT SYSTEM
ITERO
LAVA
HAPTIC TECHNOLOGY
83
 ADVANTAGES

Saves time and Opportunity Accurate

restorations Wear and chip
one visit for in- to view resistant
office systems occlusion created on
digital models. CAD/CAM
derived models

No layering/ Cross
baking No casting / Cost
infection
errors soldering errors effective
control
84
CEREC

CEREC stands for Ceramic Reconstruction

First system introduced was CEREC 1 in
1986
The CEREC 1,2 (1994) and 3 (2000) systems
(Sirona Dental)

85
E4D (D4D TECH)
Takes several images, using a red light
laser to reflect off the tooth surface
Requires the use of powder in some
limited circumstances.

86
 DCS PRECIDENT SYSTEM

oDesigned for metal copings for PFM &

FPD
oThe surface is acquired precisely and
without contact by means of a
semiconductor laser
oEasy to use software is employed for the
three dimensional design of the restoration.
oFully automatic milling machine mills the
framework
87
ITERO
The ITERO scanner is a device that is
uses a camera that take several views
(stills), and uses a strobe effect as well
as a small probe that touches the tooth to
give an optimal focal length.

88
LAVA
•Introduced in 2002.
•Used for fabrication of Zirconia framework for
all ceramic restoration.
•It uses a laser optical system to digitalize
information.
•Chairside Oral Scanner (LAVA COS, 3M ESPE)
takes a completely different approach using a
continuous video stream of the teeth

89
 HAPTIC
TECHNOLOGY
This is a virtual wax up system where
the technician can sit in front of a
computer screen looking at a 3D model
and holding a computerized wax spatula
(actually an elaborate computer mouse)

90
 A good impression and an accurate die are
the first step towards the fabrication of an
CONCLUSION accurate restoration whether its inlay, onlay or
crown.
Proper selection of the die /cast material and
its manipulation are important to achieve
accuracy in the die/cast.

91
 Phillips Science Of Dental Materials 12th Edition
Skinner’s Phillips Science Of Dental Materials 8th
Edition

REFERENCES Craig’s Restorative Dental Materials

Dimensional accuracy of seven die materials
Brian J Kenyon et al ,Journal of prosthodontics 2005

92
93