FABRICATION OF THE

3-UNIT METAL-CERMAIC
FIXED PARTIAL DENTURE

Andrea D. Jackson, DDS, MS, FACP

Howard University College of Dentistry
GOAL:
Expose the student to the laboratory fabrication of a posterior three-unit
metal – ceramic fixed partial denture. The student will also be exposed to the
soldering procedure for gold and ceramo - metal alloys and the uses of solder.

OBJECTIVES:
The student upon completion of the instruction session and suggested
reading assignments should be able to:

A. Understand the requirements for the wax pattern of a three-unit metal – ceramic fixed partial
denture.
B. Understand the concept of cut-back for porcelain application in the wax pattern
C. Understand the various pontic designs.
D. Understand the indirect spruing procedure and the reason for it.
E. Understand and select the proper investment for metal – ceramic alloys and
the investing procedures
F. Understand the burnout, casting, and divesting procedure and how it differs from gold alloys.
H. Understand the finishing procedure and the preparation of the surface for porcelain application.
I. Understand the reasons for uses of solder
J. Understand the process involved in soldering
K. Understand the difference between pre and post solder
L. Understand the classification and requirements of a solder
Clinical Considerations
 Clinical execution of
tooth preparation
 Finish-line design
 Proper axial reduction
 Proper occlusal/proximal
reduction
 Reduction appropriate for
selected restorative
materials
 Clinical procedures necessary
for proper laboratory
fabrication
 Impression making
 Placement of retraction cord
 Capturing details of
preparation
 Inter-occlusal registration
 Articulation of cast
TERMS/DEFINITIONS

 Framework – Fixed  Coping – single tooth

partial denture or metal thimble
occlusal single unit
Sequence of Procedures and Clinical
Considerations:
 Tooth
Preparation/Design
 Combination
 Shoulder
 Chamfer
 Location
 Proper Taper
 Adequate tooth reduction
 parallelism
Metal-ceramic restoration design

 Metal-Ceramic
Restoration
 Ceramic layer
 Metal understructure
 Framework
 Copings
 Esthetics
LABORATORY PROCEDURES

 Waxing
 Wax add-on technique
 Full-cast crown
 PFM crown
 Pontic
 Full anatomic wax-up
 Specifications for FPD
 Tooth #19 – full cast metal retainer
 Tooth #20 – PFM pontic
 Tooth #21 - PFM
LABORATORY PROCEDURES

 Wax cutback of pontic and retainer unit

 Well-rounded
 No undercuts
 No concavities
 No sharp corners
 No angles
 Finished Wax Patterns
 No inner surface defects
 Smooth, polished outer surfaces
COPING/FRAMEWORK DESIGN

 There are four features of importance to be

considered when designing the metal coping for a
metal-ceramic restoration:
 1.Thickness of metal underlying and adjoining the
porcelain
 2.Placement of occlusal and proximal contacts
 3.Extensions of the area to be veneered for
porcelain
 4.Design of the facial margin
LABORATORY PROCEDURES

 Coping design
 Thin porcelain of uniform thickness
 Rigid metal
 Convex surfaces
 Noble vs. base metals
Dental porcelains (which are, chemically
speaking, glasses) resist compressive
loading but tend to succumb to tensile
stress.

Therefore, the metal substructure must

be designed so that any tensile stresses
in the porcelain are minimized.
Ideally, an esthetic restoration should wear at approximately the same
rate as the enamel it replaces (about 10 µm per year5.) In addition, the
restoration should not increase the wear rate of an opposing enamel
surface.

Dental porcelain is more abrasive of enamel than of other restorative

materials (e.g., gold or amalgam, and has been implicated in severe
occlusal wear, particularly when the porcelain is not glazed or highly
polished.

This factor should be considered whenever a metal-ceramic restoration

is being designed.
Restorations with porcelain occlusal surfaces
must be planned carefully. Although they are
esthetically very acceptable, these restorations
have disadvantages, especially wear of the
opposing enamel.
Types of Facial Margins

1. Metal margins
1. – unesthetic
2. Porcelain margins on
metal collar
1. – over contoured
3. All porcelain margins
1. – most esthetic
To avoid fracture, the thickness of a ceramic veneer must not exceed 2
mm; however, a To avoid fracture, the thickness of a ceramic veneer
must not exceed 2 mm; however, a minimum thickness of 1 mm is
needed for an esthetically pleasing restoration.
Coping Design - Thickness of
Metal
 Thin uniform thickness of porcelain supported by
rigid metal is strongest
 Absolute minimum thickness of porcelain is .7mm
 Desirable thickness for porcelain is 1mm
 Minimum thickness with good esthetics
 Always compensate with extra thickness of metal
when the tooth preparation allows for more
clearance
 Maximum restoration strength and longevity is
achieved by coping rigidity
Coping design continued
 Surface should be convex
 Occlusal contact must be
1mm from porcelain-metal
junction
 Minimum thickness is .3 -.5
mm for noble metals
 Higher yield strength base
metals copings can be as thin
as .2mm
 The ultimate goal of 1mm of
uniform porcelain thickness
will determine thickness of
coping
 Proximal contacts on anterior
teeth should be in porcelain
for esthetic reasons
 Porcelain opposing natural
teeth can cause wear of the
opposing teeth-must make
patient aware that a
restoration may be needed in
the future
Full contour wax- up and cut-back
The correct steps in the fabrication of a metal-
ceramic restoration: A, full-contour wax pattern;
B, coping wax pattern cut back; C, porcelain
addition to metal coping.
If the coping pattern (A) is the first step in
fabrication, the porcelain veneer on the final
restoration may have contours that are not
continuous with those of the unveneered coping
(B).
Full contour > > > Cut - Back
METAL – PORCELAIN DESIGN
CUT BACK >>>COPING DESIGN
Alloys
Classification for Dental Casting Alloys

Noble metal content: Au, Pt, Pd

(minimum percentage by weight)
 High-noble metal
 60% (>40% gold)
 Noble metal
 25% (no gold requirement)
 Predominantly base metal
<25% (no gold requirement)
 Au, gold; Pd, palladium; Pt, platinum.
Alloys Used for Fabricating
Metal-Ceramic Restorations
 High noble
 Gold-platinum-palladium
 Gold-palladium-silver
 Gold-palladium
 Noble
 Palladium-silver
 High palladium
 Predominantly base
 Nickel-chromium
 Nickel-chromium-beryllium
 Cobalt-chromium
Dental Casting Alloys
 Classifications
 High-Noble metal content
 Noble-noble metal content of 60% or greater. At least 40% of the alloy must be
gold.

Noble metals
 must be at least 25% noble metal.

Predominately Base
 a noble metal content of less than 25%.

 Cost
 Precious
 Semi-precious
 nonprecious
Titanium Alloys
 Titanium based alloys have been studied
since the late 1970’s as potential casting
alloys.
 Advantages of titanium:
 Excellent bio-compatibility and corrosion
resistance
 Titanium oxide surface
 Low density in comparison to gold or palladium
resulting in lighter and possibly less expensive
restorations
Titanium Disadvantages

The dental casting of titanium and titanium

alloys poses special problems because of the
high melting point of titanium (1668° C)

Its strong tendency to oxidize and react with

other materials.

Special casting machines needed that provide either a

vacuum environment or an argon atmosphere
must be used.
Dental Casting Alloys

 Predominantly base alloys

 Noble metal < 25%
 Challenge to dentists and technicians
 Physical properties
 Handling characteristics
 Fabrication techniques
 Higher fusing elements
 higher melting temperature 2300-2600 degrees
Fahrenheit
 Necessitates use of gas-oxygen torch and phosphate-
bonded investment with high-heat burnout
Titanium disadvantages

 Selecting a dental laboratory experienced in

fabricating these castings is essential, and such
dental laboratories are not common in the United
States. Further research is needed to optimize the
metallurgical structure and casting technology for
titanium alloys,
Base Metal Alloys

 The potential health problems associated with

beryllium- and nickel-containing alloys have
led to the development of another alternative
base metal alloy system: cobalt-chromium.

 The representative Co-Cr alloys have higher

hardness than the Ni-Cr alloys suggests that
finishing restorations made with the former
alloys may be more difficult.
Clinical
Case
LABORATORY INSTRUMENTS FOR
FABRICATION OF CAST RESTORATIONS
 CONSTRUCTION OF
WORKING CASTS and
die
 CONSTRUCTION OF A
WAX PATTERN
LABORATORY INSTRUMENTS FOR
FABRICATION OF CAST RESTORATIONS
 CONSTRUCTION OF
WORKING CASTS
 CONSTRUCTION OF A
WAX PATTERN
LABORATORY PROCEDURES

 Pontic Design
 Modified ridge lap pontic
 Other pontic designs
 Saddle
 Hygienic
 Ovate
PONTIC DESIGN
Size and shape of connectors

Posterior Anterior compared to posterior

METAL – CERAMIC RELATIONSHIP

The melting range of the alloy used in the coping must be 170 to
280°C (300 to 500°F) higher than the fusing temperature of the
porcelain applied to it.

The metal coping is an important part of the metal-ceramic

restoration, and one that unfortunately is often overlooked. Its
design can have an important effect on the success or failure of the
restoration.
LABORATORY PROCEDURES

 Spruing  Patterns for metal-ceramic fixed

partial dentures must be sprued
 Indirect (Runner Bar by an indirect method because
the alloys used fuse and solidify at
Technique) much higher temperatures.
 Feeder sprues  Because the ambient air is much
 Transverse bar colder than the molten metal, the
exposed button is likely to solidify
 Manifold sprues while the metal at the center of
the ring is still liquid.
 Direct
 This means that the button
 Main sprues cannot serve as a reservoir to
prevent shrink-spot porosity.
 6 mm from wax pattern to Instead, a bulky horizontal runner
end of ring bar is placed between crucible
 6 mm from top of crucible former and pattern.
former
runner bar – stabilizes pattern; serves as reservoir for solidification and contraction,
equalizes flow of metal through all parts of mold,
Pattern for a metal-ceramic fixed
partial denture is sprued indirectly.
The feeder sprues and the horizontal
runner are 8 gauge, and the
manifold sprues are 10 gauge.
Molten alloy swirls through the manifold system,
raising the temperature of the surrounding invest-
ment (shaded area).
LABORATORY PROCEDURES
INVESTING
 Surrounding wax pattern with
material that duplicates its
shape and anatomic features
 Requirements
 Reproduce precisely
 Sufficient strength to withstand
burn-out/casting
 Expand to counter solidification
shrinkage
 Solidification shrinkage of metal:
multi-metal shrinks as cooling
occurs
 Smaller casting as a result
 Expansion of Mold (> original
pattern)
 4 mechanisms
1.Setting expansion (silica particles
interfere with forming crystalline
structure of gypsum-bonding)
2.Hygroscopic expansion (hydration
process)
3.Wax pattern expansion
4.Thermal expansion of the
investment
LABORATORY PROCEDURES
It may be necessary to paint phosphate-bonded
investment into the wax pattern with a small brush.

 Investing
 De-bubblizer
 Reducing surface tension
 Liner
 Cellulose ***
 Unrestricted thermal expansion
 Ceramic
 Mixture
 60 grams powder : 9.5 cc liquid
 Mix under vacuum (vac-u-spat)
 Bench set for one hour after
investing
 Scrape top of casting ring after
setting
 Allow gases to escape during
burn-out
LABORATORY PROCEDURES
 Phosphate bonded
investment
 Higher fusing alloys
 Stronger & withstands
higher temperatures
 Used for investing casting
alloys with higher
temperatures
 Silver palladium
 Gold platinum
 Gypsum bonded
investment
 fuse <1975 degrees
Fahrenheit
 Gold alloys
 Type I: small inlays
 Type II: larger inlays and
onlays
 Type III: onlays, crowns,
short-span FPD
 Type IV: long-span FPD;
thin veneer crown; RPD
LABORATORY INSTRUMENTS FOR
FABRICATION OF CAST RESTORATIONS
 CONSTRUCTION OF
WORKING CASTS
 CONSTRUCTION OF A
WAX PATTERN
 INVESTING AND
CASTING
INVESTED WAX PATTERN
 LABORATORY PROCEDURES
BURNOUT
 Removal of wax pattern to create mold into which molten alloy is placed

 Thermal expansion of the mold

 Investment allowed to harden,
 Scrape top to allow gasses to escape
 Place in oven at 600 degrees F for 30 minutes
 Then to 1300 degrees Fahrenheit for1 hour
 If longer, investment may start to break down
 Investment and ring expand to compensate for shrinkage
LABORATORY PROCEDURES
 Casting
 -Crucibles
 -Gas-Oxygen systems
 -Induction casting machine
 -Electric melting machines
As the alloy begins to solidify, the heat around the
manifold (dark shading) keeps it molten longer,
preventing porosity in the bridge.
)>

Gas-air torches for lower temperatures

LABORATORY PROCEDURES
 Finishing
 Divesting  Remove sprue and button
from casting
 Bench cool for 1 hour
 Use stones, sandpaper, and
 Break investment with
burs to finish
pointed instrument
 Aluminum oxide abrasive
to clean casting
 Ultrasonic cleaning

Sprue immediately adjacent to the

casting is removed with a separating
disc.
LABORATORY PROCEDURES

 Polishing
 Silicone wheels and cones
 Abrasive paste or
compound

 Common shapes of abrasive stones are:

cone (CN), flame (FL), cylinder (CY),
barrel (BA), wheel (WH), inverted cone
(IC), knife edge (KN), round (RD), round
edge (RE).
CASTING DEFECTS
LABORATORY INSTRUMENTS FOR
FABRICATION OF CAST RESTORATIONS
 CONSTRUCTION OF
WORKING CASTS
 CONSTRUCTION OF A
WAX PATTERN
 INVESTING AND
CASTING
 PREPARATION FOR PORCELAIN
APPLICATION – preparing the metal
Do not use any polishing compounds,
The coping thickness is checked as they may contaminate the surface
with an Iwanson thickness gauge. of the metal to be veneered later.

The veneering area is

prepared with aluminum
oxide stones.
PREPARING THE METAL
The final step in metal preparation is reduction
of the oxide layer on the part of the coping to be  Must be cleaned and
veneered with porcelain by air abrading with . uncontaminated from
50 μm aluminum oxide.
oils from the skin or
debris from finishing
with steam
Metal framework finishing
LABORATORY INSTRUMENTS FOR
FABRICATION OF CAST RESTORATIONS
 CONSTRUCTION OF
WORKING CASTS
 CONSTRUCTION OF A
WAX PATTERN
 INVESTING AND
CASTING
 PORCELAIN
APPLICATION
Heat Treatment – Oxidation
cycle
 Coping is placed in furnace and the
temperature raised from 300 – 400 oC
 Directions are alloy specific
 Removal of hydrogen gases that was incorporated
in the casting process
 Porcelain buildup - Opaque
application
Done to mask the metal, supply the base shade, and
creates the initial bond
The veneering surface of the coping Two layers of opaque are baked
is wetted with distilled water or special individually
liquid recommended by the manufacturer.
Application of Dentin porcelain/
Body porcelain
 Made with a brush
 Tissue is used to absorb water
 Over build contour to compensate for shrinkage
 A sable brush is used for condensing and final shaping
Cut back and apply Incisal/
enamel porcelain
 Create translucency and esthetics
 Done with a spatula on the inciisal edges and proximal contact areas
cutback
Cut back and apply Incisal/
enamel porcelain

Incisal porcelain ready for Adding small amount to proximal

firing Contact before firing
Firing / Baking porcelain

 Requires more than one bake to make

adjustments in the contours
 A clean green stone is used for contouring
Finishing Porcelain
 Shade modification done prior to final finish if necessary

 Auto glaze – glazes itself during firing process

 Must avoid over firing

 Applied glaze - a low fusing clear porcelain is applied and baked

to the surface

 Polishing – done on small areas that may have been adjusted in

the mouth
 May be less destructive to opposing tooth structure
 *Finishing the metal is the same as any other metal
LABORATORY INSTRUMENTS FOR
FABRICATION OF CAST RESTORATIONS
 CONSTRUCTION OF
WORKING CASTS
 CONSTRUCTION OF A
WAX PATTERN
 INVESTING AND
CASTING
 PORCELAIN
APPLICATION
Bisque bake try-in
Cementation of definitive
restoration
JOINING METALS/ SOLDERING
 The addition of filler  Soldering
 Uses:  Classification
 Soldering/joining units of  Fineness (gold content)
conventional gold alloy  Characteristics
(FPD’s, splints)  Corrosion resistant
 Adding proximal contacts  Lower fusing
 Repairing casting voids  Non-pitting
 Soldering porcelain fused  Strength
to metal alloys
 Free-flowing

Welding (melting)
Pre and Post Soldering for metal
ceramic restorations
 Pre-Soldering  Post – soldering
 Done prior to placing the  Done after the porcelain is
 porcelain placed

Wax patterns for metal-ceramic fixed partial dentures are

invested and cast as one unit whenever possible because of the
difficulty encountered in soldering the alloys used for this type of
restoration
Gold Solder Fineness

 Refers to parts per thousand of the solder that is

gold
 Ex:
600 fine solder is 600 parts of gold per 1,000 or
60% gold. (minimum that should be used is 580 fine)
The higher the fineness, the higher the melting range and the
more corrosion resistance
A casting alloy is designated by carat (refers to parts per 24
ex: 18K = 75% gold
A solder designated 18K means it should be used with 18K
casting alloy
Soldering

 Solder should possess a fusion temperature

that is about 60 degrees C (100 – 150 F) below
that of the metal being soldered
 Four- and five-unit fixed partial dentures
joined by soldering have better-fitting
margins than do one-piece castings of the
same length.
 Any fixed partial denture larger than three
units should still be cast in two pieces and
soldered.
The SOLDERING procedure
An index is made in the mouth, the restoration is invested and soldered.

1. Applying anti-flux 2. Heating the area to be joined

3. Adding solder 4. Completed solder joint