DENTURE BASE MATERIALS AND PROCESSING TECHNIQUES

Dr Narendra Basutkar

CONTENTS Definations Brief history of evolution of denture base materials Classification of denture base materials Ideal requirements of denture base materials Denture base resins and processing techniques Metallic denture base materials Review of litreture Recent advances Summary and conclusion References

Definitions
denture base: the part of a denture that rests on the foundation tissues and to which teeth are attached denture base material: any substance of which a denture base may be made denture: an artificial substitute for missing natural teeth and adjacent tissues denture foundation area: the surfaces of the oral structures available to support a denture

BRIEF HISTORY OF EVLOUTION OF DENTURE BASE MATERIALS WOOD

For years, dentures were fashioned from wood .

Wood was chosen -readily available -relatively inexpensive -can be carved to desired shape Disadvantages -warped and cracked in moisture -esthetic and hygienic challenges -degradation in oral environment
Wooden denture believed to be carved out of box wood in 1538 by Nakoka Tei a Buddist priestess

BONE
Bone was chosen due to its availability, reasonable cost and carvability . It is reported that Fauchard fabricated dentures by measuring individual arches with a compass and cutting bone to fit the arches . It had better dimensional stability than wood, esthetic and hygienic concerns remained.

IVORY

Denture bases and prosthetic teeth were fashioned by carving this material to desired shape Ivory was not available readily and was relatively expensive. Denture bases fashioned from ivory were relatively stable in the oral environment They offered esthetic and hygienic advantage in comparison with denture bases carved from wood or bone.

G.Fonzi an italian dentist in Paris invented the Porcelain teeth that revolutionized the construction Of dentures.Picture shows partial denture of about 1830,porcelain teeth of fonzis design have been Soldered to a gold backing.

PORCELAIN Porcelain denture bases were relatively expensive During subsequent years secrets of porcelain denture became known and it became common and inexpensive. ADVANTAGES over wood, bone , ivory were -Could be shaped using additive technique rather than subtractive (carving). -Additive technique facilitated correction of denture base surface. -this permitted more intimate contact with underlying soft tissues. -Could be tinted to simulate the colors of teeth and oral soft tissues. -stable in oral environment. -Minimal water sorption, porosity, and solubility. -Smooth surface provided hygienic properties. Among the DRAWBACKS brittleness was most significant, fractures were common, often irreparable.

One piece porcelain upper denture crafted by Dr John Scarborough,Lambertvill e,New Jersey 1868.

In 1794 John Greenwood began to swage gold bases for dentures. Made George Washington's dentures.

George Washington's last dental prosthesis. The palate was swaged from a sheet of gold and ivory teeth riveted to it. The lower denture consists of a single carved block of ivory. The two dentures were held together by steel Springs.

In 1839 an important development took place CHARLES GOODYEAR discovered VULCANIZATION of natural rubber with sulphur(30%) and was patented by Hancock in england in 1843. NELSON GOODYEAR (brother of charles goodyear) got the patent for vulcanite dentures in 1864. . They proceeded to license dentists who used their material, and charged a royalty for all dentures made. Dentists who would not comply were sued.
A set of vulcanite dentures worn by Gen. John J. (Blackjack) Pershing, The Goodyear patents expired in 1881, and the company commander of the American did not again seek to license dentists or dental products. Expeditionary Forces in France during the First World War

Vulcanite dentures were very popular until the 1940s, when acrylic denture bases replaced them.

In 1868 John Hyatt, A US Printer, discovered the first plastic molding compound, called celluloid. He made it by dissolving nitrocellulose under pressure In 1909, another promising organic compound was found. This was phenol formaldehyde resin discovered by Dr. Leo Backeland .
Celluloid upper denture 1880,celluloid as a Substitute for vulcanite was unsuccessful as It absorbs stains and odors in the mouth, Gradually turns black and was flammable.

 In 1937 Dr. Walter Wright gave dentistry its very useful resin.
It was polymethyl methacrylate which proved to be much satisfactory material tested until now.

By 1946, 98% of all denture bases were fabricated from PMMA

Dentures made of polymethyl methacrylate

Classification of denture base materials

Metallic denture base materials eg. Cobalt- chromium, gold alloys, aluminium, stainlesssteel Non metallic denture base materials eg. Acrylic resins Temporary denture base materials eg. Self cure acrylic resins, shellac base plate Permanent denture base materials eg. Heat cure acrylic resins, metallic denture base

Ideal requirements of denture base materials

Final report of the workshop on clinical requirements of ideal denture base material 1. Physiologic compatability Nontoxic Noncarcinogenic Nonallergenic Compatible with physiologic requirements of mucous membranes Optimum consistency to maintain or promote tissue health Not deleterious to adjacent and underlying tissues Conducive to normal salivary flow
ATWOOD:JPD 1968 (20) 101-105

 2. Acceptability to patients' senses Acceptable to all five senses-sight, sound, smell, taste, and touch Able to duplicate and simulate oral tissues as nearly as possible Possessing wide selection of color Possible for esthetics to be easily modified Color stable Odorless Tasteless Possessing instantaneous temperature conductivity Light weight Possessing sensation of natural texture 3. Functional usefulness Rigid enough so that teeth penetrate the bolus No interference with oral functions of chewing, swallowing, self cleansing, singing, speech, sneezing, breathing, laughing, coughing, etc.

 4. Hygienic factors

Sterilizable Resistant to stain, calculus, and adherent substances Nonporous to microorganisms Low fluid absorption Wettable (low surface tension) Easily cleaned
Not affected by oral environment-bacteria, food, medicines, etc. Unbreakable (not brittle) Not crazing Dimensionally stable and statically stable Minimal internal strain Good bond between different base materials Good bond between base and teeth Not flammable Resistant to weak acids and alkalies Resistant to abrasion and wear Resistant to strain Long lasting

5. Durability

Adaptability to clinical problems Adjustable Easily polished Easily repaired Easily relined May need more than one type of material May use combinations of materials (soft for tissues, hard for teeth) Choice of hardness or softness (various materials for different situations)

7. Cost factors Simple to manipulate Simple to process Inexpensive equipment for processing Average skill required for processing No separation medium required Easily separated from cast Moderate cost of fabrication Good shelf life Predictable properties

DENTAL POLYMERS Polymer is chemical compound consisting of large organic molecules formed by the union of many repeating smaller monomer units.

CHEMISTRY OF POLYMERIZATION
Chemical reactions in which monomers of a low molecular wt. Are convert into chains of polymers with a high molecular weight is called polymerization. The most common polymerization reaction for polymers used in dentistry is addition polymerization. ADDITION POLYMERIZATION; The monomers are activated one at a time and add together in sequence to form a growing chain.

Stages in addition polymerization INDUCTION PROPOGATION CHAIN TRANSFER TERMINATION

Induction
For an addition polymerization to begin, a source of free radical is required. Free radicals can be generated by activation of radical producing molecule using. Second chemical Heat Visible light Ultraviolet light The most commonly employed iniator is benzyol peroxide which is activated rapidly between 50 0C and 100oC

PROPAGATION The resulting free radical monomer complex acts as a new free radical center which is approached by another monomer to form a dimer, which also becomes a free radical. CHAIN TRANSFER The active free radical of a growing chain is transferred to another molecule (eg monomer or inactivated polymer chain) and a new free radical for further growth is created termination occurs in the latter.

TERMINATION

Can occur from chain transfer. Addition polymerization reaction is terminated by -Direct coupling of two free radical chains ends -Exchange of hydrogen atom from one growing chain to another.

INHIBITION OF ADDITION REACTION

Addition of small amount of Hydroquinone to the monomer inhibits spontaneous polymerization if no initiator is present and retards the polymerization in the presence of an initiator. Amount added is 0.006% or less.

COPOLYMERIZATION When two or more chemically different monomers each with desirable properties can be combined to yield specific physical property of a polymer .eg small amount of ethyl acrylate may be co-polymerized with methyl methacrylate to alter the flexibility and fracture resistance of a denture.

DENTURE BASE RESINS

Pure PMMA is a colorless, transparent solid. To facilitate its use in dental applications, the polymer may be tinted to provide almost any shade and degree of translucency

Heat activated denture base resins

Composition Powder - prepolymerized spheres of PMMA - small amount of benzoyl peroxide - responsible for starting the polymerization process initiator Liquid - Methyl Methacrylate - small amounts of hydroquinone - inhibitor it prevents undesirable polymerization during storage - glycol dimethacrylate.. Cross linking agent.. 1-2%

Compression molding technique

Preparation of the mold Application of separating medium Failure to place an separating medium 1. Water from mold surface may difuse in to denture resin, it may affect the polymerization rate as well as optical and physical properties 2. Free monomer may soak into mold surface portions of investing medium may become fused to the denture base Tin foil. Most widely accepted methods time and labor intensive Paint on separating media like cellulose, lacquers, solution containing alginate compounds, soaps, starches were introduced.. Tin foil subtitutes Most popular water soluble alginate solution Produce thin, relatively insoluble calcium alginate films..

Polymer monomer ratio Of considerable importance Polimerization of MMA to PMMA yields 21% decrease in the volume of mateial,, which would create difficulties in denture base fabrication and clinical use. To minimize dimensional changes.. Resin manufacturers prepolymerize a significant fraction of the denture base resin The accepted polymer to monomer ratio is 3:1 by volume.. Using this ratio the volumetric shrinkage is limited to 6% and 0.5% linear shrinkage

Polymer monomer interaction

When mixed in proper proportions, the resultant mass passes through five distinct stages Sandy, stringy, dough like, rubbery, stiff During sandy stage, little or no interaction occurs on a molecular level. Polymer beads remain unaltered. Later, mixture enters stringy stage. Monomer attacks the surfaces of individual polymer beads. Stage charcterized by stringiness, Subsquently the mass enters a dough like stage. On molecular level incresed number of polymer chains are formed. Clinically the mass becomes as a pliable dough. It is no longer tacky This stage is ideal for compression molding. Hence material is inserted into mold cavity during dough like stage.

 Following dough like stage, the mixture enters rubbery or elastic stage. Monomer is dissipated by evaporation and by further penetration into remaining polymer beads. In clinical use the mass rebounds when compressed or stretched Upon standing for an extended period, the mixture becomes stiff. This may be attributed to the evaporation of free monomer. From clinical point, the mixture appears very dry and resistant to mechanical deformation DOUGH FORMING TIME The time required for the resin mixture to reach a dough like stage is termed the dough forming time. ANSI/ADA specification No.12 for denture base resins requires that this consistancy be attained in less than 40 min from the start of mixing process. In clinical use, the majority of resin reach a dough like consistancy in less than 10 min.

 WORKING TIME Time that a denture base material remain in the dough like stage This period is critical to compression molding ANSI/ADA Sp. No. 12 requires the dough to remain moldable for at least 5 min PACKING Placement and adaptation of denture base material within the mold cavity is termed packing Overpacking- leads to excessive thickness and malpositioing pf prosthetic teeth Underpacking- leads to noticeable denture base porosity Trial packing is done to ensure proper packing of resin mass in the mold. After the final closure of the flasks, they should remain at room temperature for 30- 60 min. it is called bench curing

 Bench curing It permits equalization of pressure throughout the mold Allows more time for uniform dispersion of monomer throughout the mass of dough If resin teeth are used, it provides a longer exposure of resin teeth to the monomer producing a better bond of the teeth with the base material

 POLYMERIZATION PROCEDURE/ CURING When heated above 60 c, molecules of benzoyl peroxide decompose to yield free radicals. Each free radicals, rapidly reacts with an available monomer molecule to initiate polymerization Heat is required to cause decomposition of benzoyl peroxide. Therefore heat is termed as activator. Decomposition of benzyol peroxide molecule yields free radicals that are responsible for initiation of chain growth. Hence it is termed as initiator

 Temperature rise The polymerization of denture base resin is exothermic and the amount of the heat evolved may affect the properties of the processed denture bases. Because resin and dental stone are relatively poor thermal conductors, the heat of reaction cannot be dissipated. Therefore the temperature of resin rises well above the temperature of investing stone and surrounding water. It should be noted that temperatue of resin not allowed to exceed the boiling point of the monomer (100.8oC) which produces significant effects on the physical characteristics of the processed resin.

 1. 2. 3.

Curing cycle Following curing cycle have been quite successful Processing in a constant temperature water bath at 74oC for 8 hrs or longer with no terminal boil Processing in a 74 0C water bath for 8 hrs and then incresing the temperature to 100oC for 1 hr. Processing resin at 74oC for approx 2hrs and increasing the temperature of water bath to 100oC for 1 hr. Following the completion of curing, the denture flasks should be cooled slowly to room temperature Rapid cooling may result in warping of denture base because of difference in thermal contraction of resin and investing stone. Hence flasks should be removed from the water bath and bench cooled for 30 min.

 Polymerization via microwave energy First reported by Kimura et.al Resins can also be polymerized by microwave energy This technique employs a specially formulated resin and a non metallic flasks FRP Flask [ Fiber Reinforced Plastic flasks] Advantages: Cleaner and faster polymerization.. 3 mins Minimal color changes Less fracture of artificial teeth and resin bases Superior denture base adaptability

 Bernard levin et al [ JPD 1989;61: 381-383] Compared conventional water bath heat cure method with microwave and found no noticeable difference between dentures produced by microwave processing and conventional water bath processing. He listed following disadvantages of microwave processing Flasks are expensive and have tendency to break down after processing several dentures. The polycarbon bolts tend to break if tightened too firmly.

Injection molded polymers

These are made of Nylon or Polycarbonate.

The material is supplied as a gel in the form of a putty It has to be heated and injected into a mold Flask is then placed into water bath for polymerization as the material polymerizes addition resin is introduced into the mold cavity. This process offsets the effects of polymerization shrinkage. Available data and clinical information indicate denture bases fabricated by injection molding may provide slightly improved clinical accuracy.

Equipment is expensive.

The SR-Ivocap system uses specialized flasks and clamping presses to keep the molds under a constant pressure of 3000 lbs

1. 2.

Chemically activated denture base resins Chemical activators are used to induce polymerization. Does not require thermal energy and therefore may be completed at room temperature. Hence often referred to as cold curing, self curing or autopolymerizing resins. Chemical activation is accomplished through the addition of a tertiary amine such as dimethyl- para- toluidine to the liquid. Upon mixing, the tertiary amine causes decomposition of benzoyl peroxide. Consequently, free radicals are produced and polymerization is initiated. There is greater amount of unreacted monomer which creates two major difficulties.. It acts as plasticizer that results in decreased transverse strength of denture resin. Residual monomer serves as a potential tissue irritant, thereby compromising the biocompatibility of the denture base.

Technical considerations Most often molded using compression technique. Mold preparation and resin packing are essentially same. Supplied in form of powder and liquid. Mixed according to manufacturers instructions. Working time for self cure resin is shorter than heat cured resins. Refrigating the liquid component or mixing vessel before mixing process can prolong the working time. Processing considerations Following final closure of the denture flask, pressure must be maintained throughout polymerization process. Intial hardening of resin occurs within 30 mins of final closure. To ensure sufficient polymerization, the flask should be held under pressure for minimum 3 hrs Resins polymerized via chemical activation generally display 3-5% free monomer where as heat activated resins 0.2-0.5% free monomer.

Fluid resin technique Walter Shepard [ JPD 1968;19: 562-564] Employs a pourable chemically activated resin Advantages Improved adaptation to underlying soft tissues. Decreased damage to prosthetic teeth and denture base during deflasking Reduced material costs Simplification of flasking, deflasking, finishing procedure Disadvantages Noticeable shifting of prosthetic teeth during processing Air entrapment Poor bonding between denture base and acrylic teeth Technique sensitivity

 Fluid denture resin processing in a rigid mold [ JPD 1973; 30; 339-345 ] Koblitz FF et al described a fluid resin processing technique using rigid, modified gypsum investment as replacement for hydrocolloid investment. Advantages Method requires no specialized equipment such as metal flasks or hydrocolloid conditioning apparatus The technique eliminates the time consuming step of sorting and replacing artificial teeth in as hydrocolloid mold.

 Light activated denture base resins This material has been described as a composite having a matrix of urethane dimethacrylate and microfine silica Visible light is the activator Camphoroquinone serves as the initiator for polymerization Supplied in sheets and rope forms and is packed in light proof pouches. Technique Teeth are arranged, and the denture base is molded on an accurate cast. Subsequently the denture base is exposed to high intensity visible light source for an appropriate period Following polymerization, the denture is removed from the cast, finished and polished in a conventional manner.

 Properties of denture base resins

METHYL METHACRYLATE
Methyl methacrylate is a transparent liquid at room temp. Physical properties

-Molecular wt=100
-Melting point=-48 C -Boiling point=100.8 C

-Density=0.945g/ml at 20 C
-Heat of polymerization=12.9 Kcal/mol

POLYMETHYL METHACRYLATE Transparent resin, transmits light in uv range to a wavelength of 250 nm. Hard resin knoop hardness no of 18 to 20. Tensile strength is 60 MPa Density is 1.19 g/cm cube. Modulus of elasticity 2.4 GPa(2400 MPa) It is chemically stable and softens at 1250C It can be molded as a thermoplastic material between 125oC and 200o C Depolarization takes place at approx 450oC . Absorbs water by imbibition Non crystalline structure possess high internal energy.

 Strength The stress at which fracture occurs is called the ultimate strength. Resins are typically low in strength, however they have adequate compressive and tensile strength for complete or partial denture applications. Compressive strength- 75 Mpa Tensile strength- 52 Mpa Strength is affected by Composition of the resin Technique of processing Degree of polymerization Water sorption Subsequent environment of the denture Impact strength: it is the measure of energy absorbed by a material when it is broken by a sudden blow. Addition of plasticizers increase the impact strength.

 Hardness Hardness is the resistance of a material to indentation. Resins have low hardness. They can be easily scratched and abraded. The knoops hardness is obtained by measurement of the length of an indentation from an diamond indenter and calculating the number of kilograms required to give an indentation of 1mm2. Heat cured resin- 18-20 KHN Self cured resin- 16-18 KHN Modulus of elasticity It is the measure of stiffness of a material. It is equal to the ratio of the stress to the strain. Resins have sufficient stiffness [ 2400MPa] for use in complete and partial dentures.

 Polymerization shrinkage When MMA monomer is polymerized to form PMMA.. Results in 21% volumetric shrinkage. To reduce this high % of shrinkage polymer powder is supplied in prepolymerized beads form which accounts for only 7% of volumetric shrinkage. .distributed uniformly to all surfaces, hence the adaptation of denture bases to underlying soft tissues is not significantly affected. Processing shrinkage Due to stresses induced during processing 0.26% for self cure resin 0.53% for heat activated resin

 Porosity May compromise physical, aesthetic and hygenic properties of processed dentures. Porosity may be Internal / external Internal porosity: Is in form of voids or bubbles within the mass of processed resin. It is confined to thick portions of denture base. Results from vaporization of unreacted monomer and low molecular wt. polymers, when the temperature of the resin reaches or surpasses the boiling point of these species. External porosity: due to Inadequate mixing of powder liquid components. Inhomogenity of resin mass Inadequate pressure or insufficient material Air inclusions incorporated during mixing procedures.

 1. 2.

Water sorption PMMA absorbs relatively small amounts of water when placed in aqueous environment. Absorption is facilitated by primarily by diffusion mechanism. Water molecules occupy positions between polymer chains forcing the polymer chains apart. The introduction of water molecules in the polymerized mass produces two important effects It causes slight expansion of polymerized mass Acts as plasticizers PMMA exhibits a water sorption value of 0.69mg/cm2 Fortunately these changes are relatively minor and do not exert significant effects on the fit or function of processed bases. ANSI/ADA Sp. No 12, requires the weight gain following immersion must not be greater than 0.8mg/cm2 for denture base resins.

 Crazing Is formation of surface cracks on denture base resin. Crazing may be due to -Stress relaxation -Solvent action eg. Ethyl alcohol Crazing in a transparent resin imparts a hazy or foggy appearance. These surface cracks predispose a denture resin to fracture.

 Cytotoxicity of denture base acrylic resins [ JPD 2003: 90; 190-195 ] Residual monomer, resulting from incomplete conversion of monomers into polymer, has the potential to cause irritation, inflammation, and an allergic responses of oral mucosa. Clinical signs and symptoms reported include erythema, erosion of oral mucosa, burning sensation of mucosa and tongue. Effect of polymer : monomer ratio More monomer added to the mixture, the greater amount of residual monomer and therefore more potential for cytotoxicity. Effect of storage time and water immersion Sheridan et al reported that cytotoxic effect of acrylic resins was greater in first 24 hrs after polymerization and decresed with time. Therefore it is recommended that dentist soak the resin prosthesis in water for atleast 24 hrs before placing them in the patients mouth.

 Effects of polymerization cycle Reduced amount of residual monomer when polymerization time extended was observed. 7hr incubation in water at 700C followed by 1 hr at 1000 C was ideal because it provided maximum conversion of residual monomer. Auto polymerized resins exhibited higher content of residual monomer than heat polymerized resins. Lamb et al observed that levels of residual monomer were higher for specimans polymerized at 200C as compared with those at 550C. Therefore it is suggested that the autopolymerzed acrylic resins should be heat treated to decrease cytotoxic effects.

 Metallic denture base materials Advantages of cast metal denture bases over acrylic bases: Lack of bulk with more strength The metal base prevents warpage during processing. Stronger and are less subject to breakage. More accurate fit and more faithful reproduction of tissue details. Less tissue changes occur under metal bases. Dimensional accuracy. Less porous. Better thermal conductivity Show less lateral deformation in function

Disadvantages of metal bases: Greater technical costs. Difficulty of rebasing and relining Less margin for error permissible in the posterior palate seal area Increased weight for a maxillary denture Indications Despite the popularity of PMMA as a denture base there are various situations where a metallic denture base can be used: Single maxillary complete denture opposing a natural mandibular dentition Unfavourable occlusal plane Heavy anterior contacts Heavy masticatory forces

 Different metallic denture base materials: TYPE 4 extra high strength gold alloys Base metal alloys, titanium and titanium alloys, stainless steel alloys. Cobalt-chromium alloys: As early as 1949 it was estimated that nearly 80% of all partial denture appliances were cast from co-cr alloys and Ni-Cr alloys Composition: Principle elements (approx. 90%) Cobalt 60% Chromium 25% to 30% Other components: Molybdenum,Aluminium,nitrogen,Berylium,carbon& manganese Nickel chromium alloys: Nickel 70% Chromium 16% Other constituents

Chromium : Responsible for the tarnish and corrosion resistance. By forming a thin surface layer of chromium oxide. These alloys are considered to be technique sensitive Cobalt and nickel: In general cobalt and nickel are interchangeable. Melting point of Ni is 1450C and Co is 1500C Cobalt increases the elastic modulus, strength and hardness more than Nickel does. Other alloying components : Carbon: Increase in carbon content increases the hardness of Co-based alloys If the carbon content is increased by 0.2% more than the desired amount -results in a too hard and too brittle alloy not suitable for dental appliances. Whereas, a decrease of 0.2% will decrease the tensile and the yield strength. molybdenum/ beryllium (3% to 6% ) Contributes to the strength of the alloy. Lowers the melting point to improve castability

 Ni- Cr- Be alloys are popular despite the potential toxicity of beryllium and allergic potential of nickel. Reasons : 1. Ni is combined with chromium to form a highly corrosion resistant alloys. 2. Low cost of the alloys 3. Although Be is a toxic metal, dentists and patients should not be affected. Because main risk occurs in vapor form, which is a concern for technicians who melt and cast large quantities of Ni-Cr-Be alloys without adequate ventilation. 4. Ni alloys have excellent mechanical props such as high elastic modulus, high hardness.

 Titanium: Ti was developed by William Gregor of England in 1791,and was named by Martin H. Kalproth of Germany in 1795. Welhelm Kroll1930 invented useful metallurgical processes for Ti and is considered to be the FATHER of Ti dentistry. Most biocompatible alloy. Five grades are available. Grade 1 to 4 and grade 7.. Based on concentration of oxygen, iron, nitrogen and carbon Grade 1 is commercially pure titanium Most purest and softest form, low density 4.51g/cm3 Resistant to tarnish and corrosion, forms 10nm passivating oxide film spontaneously. High melting point 1668C Special casting machine with arc melting capability and an argon atmosphere is typically used along with compatible casting investment to ensure acceptable castability. Most widely used titanium alloy in dentistry Ti-6Al-4V.

 ALUMINIUM . Basically produced by the electrolysis of bauxite ore in molten cryolite bath. BACKGROUND The first know casting of an aluminum complete denture base in the US was done in 1867. Carroll presented a method for casting the aluminum base under pressure. Indications of an aluminium denture base: 1. Is an excellent choice when the natural mandibular dentition opposes the edentulous maxillary arch. 2. patients who have undergone maxillary and mandibular atrophy through years of CD use will benefit. 3. Patients who have had fracture problems with resin denture bases.

 Alloy contains 99.95% pure aluminium and 3.75% magnesium. When melted and cast electrically, the alloy has excellent casting characteristics and resistance to tarnish and corrosion. Technical considerations Wax pattern 28 gauge casting wax Burn out 1300F, Ring allowed to cool to 650F Alloy ingot melted at temperature at 1500F in electric casting machine. Al- alloy solidifies at approx 650F Ring is bench cured for 10 min prior to quenching and casting recovered.

 STAINLESS STEEL DENTURE BASE When approximately 12% to 30% chromium is added to iron the alloy is called STAINLESS-STEEL. Resistant to tarnish and corrosion because of passivating effects of chromium. Types of stainless steel Ferritic, Martensitic, Austenitic ( 18-8 steel)

Despite the difficulties in swaging ,stainless steel has some merits as a denture base material: l.Very thin denture base can be produced -figures as low as as 0.11 mm 2. The steel is fracture resistant. 3. Not heavy due to the thinness. 4.The corrosion resistance is good.
5. Good thermal conductivity.

Recent advances
RAPID HEAT POLYMERIZED POLYMER These are hybrid acrylics which have had the initiator formulated to allow for very rapid polymerization without nearly as much 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.

HIGH IMPACT RESISTANT ACRYLIC

Butadiene- styrene rubber is incorporated with copolymer of vinyl and hydroxyethyl monomer. These materials are slightly stiffer, have twice the impact strength, absorbs less water and lower linear shrinkage. But are not entirely color stable.

Recent advances
FIBER REINFORCED POLYMER Glass, carbon/graphite, aramid and ultrahigh molecular wt 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.

 Acrylic resins with improved thermal conductivity Thermal conductivity of PMMA is three times less than metals. Thermal conductivity of denture base materials is found to have an important effect on gustatory sensitivity. Thermal conductivity of acrylic based materials can be improved by introducing a more thermally conducting phase within the insulating acrylic resin matrix. Eg. Al2 O3, porcelain whiskers JPD 1998: 20; 278-

VALPLAST Nylon like material Nearly unbreakable, pink colored like gum Can be built quite thin, can form not only denture base but the clasp as well. Valplast is a flexible denture base resin that is ideal for partial dentures and unilateral restorations. The resin is a biocompatible nylon thermoplastic ,it eliminates the concern about acrylic allergies.

Review of litreture
FA PEYTON et al 1963, evaluated dentures processed by different technique. Four self cure type, seven heat cure type, three injection products, two cr-co alloys were studied. They concluded that The most accurate dentures were self cure type. And it offers simplest method and involves least amount of equipment. Second best was found to be heat cure type, but the total processing time is long. Injection molding tech. Required highly trained personnel and equipment is more complicated and expensive.

 ROBERT E OGLE et al 1999, compared incisal pin opening, dimensional accuracy, and laboratory working time for dentures constructed by injection system with conventional compression molding technique. They concluded that Injection molding method produced a significant smaller incisal pin opening over standard compression molding technique. Injection molding technique was more accurate method for processing dentures. There were no appreciable difference in laboratory working time between the two.

 FD MIRZA 1961, clinically evaluated the dimensional stability of heat cure and self cure type. Heat cure dentures were processed with conventional compression molding technique and self cure resin were processed with fluid resin tech. He concluded that, the clinical fit of auto polymerized dentures was equally as good as that of heat cured dentures, even though the magnitude of linear dimensional changes of auto polymerized dentures after 3 months of use was greater than heat cured group. This continuous shrinkage may be due to greater volume of monomer employed in resin mix. The difference was statistically significant when compared with heat cured group.

 BECKER, SMITH et al 1997, compared some of the physical properties acrylic resin when processed using - all gypsum pressure molding technique - silicone gypsum molding technique - fluid resin system Concluded that Increase in thickness of acrylic resin in the palate occurs for all three processing tech. But were not noticeable clinically Fluid resin showed greatest increase in palatal thickness may be attributed to lack of force used to hold the master cast position against investment material. Color stability of the resin for all three processing tech. Passed ADA sp no.12 for acrylic resin. All three proscessing tech demonstrated the ability of the resiin to reproduce minute detail.

 A study was conducted in our dept by Dr. Goutam Shetty under the guidance of Dr. NP Patil sir. The main objective of the study were, To compare the fit of aluminium alloy denture base with the acrylic denture base and base metal denture base. To study the effect of anodization and electroplating on resistance to corrosion. Results: The results indicated the accuracy of fit of aluminium was better than base metal alloy and superior than acrylic resin. Anodized aluminium showed better resistance to corrosion than that electroplated and that without any surface treatment.

A STUDY WAS DONE IN OUR COLLEGE UNDER THE ABLE GUIDANCE OF Dr N.P.PATIL TO SEE TRANSVERSE AND IMPACT STRENGTH OF A NEW INDIGENOUS HIGHIMPACT DENTURE BASE RESIN DPI- TUFF AND ITS COMPARISON WITH MOST COMMONLY USED TWO DENTURE BASE RESINS
1. 2. 3.

Three heat cure denture base resins were compared; DPI TUFF Lucitone 199 Conventional heat cure denture base resin Total of 120 samples were prepared using short and long curing cycles - 73C and held for 90 minutes followed by boiling at 100 C for 30
minutes - In the long curing cycle the temperature was slowly raised from room temperature to 73C and held for 9 hours

They were furher divided into samples tested under dry and wet conditions.

Conclusion drawn were

The DPI- TUFF high impact denture base resin appears to be comparatively superior to the other two resins compared with mean transverse strength.

The dry strength of the samples of the materials tested show that it
is greater than after immersion of the samples in water at 37C for 1 week. The long curing cycle shows considerably higher values of transverse and impact strength as compared to short curing cycle.

A study was done in our college Under The Able Guidance of Dr N.P.PATIL to see the effect of fiber reinforcement on the dimensional changes of polymethyl methacrylate resin after processing and after immersion in water. Study was carried out to evaluate the effect of fiber reinforcement on the dimensional changes of heat cure poly(methyl methacrylate) resins and to compare the dimensional changes occurring in three types of heat cure poly (methyl methacrylate) resins after processing and after immersion on water Thirty temporary denture bases of uniform thickness and peripheral extensions in respective areas were fabricated on identical maxillary edentulous cast for each of the three group. Denture bases of all three groups showed contraction in the intercanine, intermolar, and canine to molar distances on right and left side after processing. The dimensional changes observed in the three groups after processing are in the following decreasing order- Fiber glass reinforced heat cure PMMA, High impact heat cure PMMA, Non reinforced heat cure PMMA.

The amount of space observed between the tissues was also in the above order. The denture bases after immersion in water(17 days) of all the three groups showed expansion this comensated partly for processing shrinkage.
Fiber glass reinforcement can be used clinically since the magnitude of change was less than one % which seems to have little clinical significance.

Summary and conclusion

Complete denture will continue to be an important service well into future. New materials and processes that help clinicians and dental technicians provide quality care while improving patient connivance and access will continue to be successful.

REFERENCES:

Kenneth j. Anusavice ; Phillips Science of dental material .Eleventh edition, Elsevier,2004. William J. OBrien; Dental materials and their selection. Third edition, quintessence Publishing co. 2002. Robert C. Craig John M. Powers, John C.Wataha ;Dental materials properties and manipulation,. Eight edition,2004. Robert L.Engelmeier; The dental clinics of North America-complete dentures, W B Saunders company jan 1996 vol.40 no.1 Peyton F.A., Anthony D.H., 1963: Evaluation of dentures processed by different techniques. J. Prosthet Dent.; March April 13(2): 269-282. Braden M., 1964: The absorption of water by acrylic resins and other materials. J Prosthet Dent.; March/April 14(2): 307-316

 Melvin E Ring ; ,An illustrated history of dentistry.1985 Rudd and morrow; dental laboratory procedures: 1986 2nd edition Vk subbarao ; notes on dental materials : 4th edition Atwood et al: final report of the workshop on clinical requirements of ideal denture base material ; JPD 1968(20) 101-105 Walter Shepard : fluid resin technique; JPD 1968 (19) 561 Koblitz F.F et al: Fluid denture resin processing in a rigid mold JPD1973 (30) 339 Dimensional accuracy of pour acrylic resin and conventional processing of cold cure resin JPD 1970 (24) 662-

 EW Skinner; acrylic denture base material their physical properties and manipulation. JPD 1951 (1) 161 Donald Lundquist; aluminium alloy as a denture base materials JPD 1963 (13) 102 Comparision of self curing and heat curing denture base resins JPD 1953 (3) 332 FA Peyton; evaluation of dentures processed by different technique JPD 1963 (13) 269 Cytotoxicity of denture base acrylic resin JPD 2003 (90) 190 Bernard levin et al; use of microwave energy for processing acrylic resins JPD 1989 (61) 381 Robert EO; Comparision of accuracy between compression and injection molded complete denture JPD 1999 (82) 291 FD MIRZA; Dimensional stability of acrylic resin dentures JPD 1961 (11) 848 BECKER, SMITH; comparision of denture base processing technique JPD 1977 (37) 330-