Full metal crown construction

Casting procedures

Definition :
Casting procedure is the process of converting the
wax pattern into a metal restoration ready for
cementation.
-After preparation is completed, tissue retraction is
done and an impression is taken. A stone
working cast will be obtained. Wax pattern and
spuring is carried out on the removable die.
-Investing, burning out of wax and casting of metal,
then finishing and polishing of the cast crown
will be the last step in construction of all metal
crown.

I- Wax pattern
Definition :
It is the process of rebuilding the
prepared teeth, on the removable
die, by wax using direct and\or
indirect technique.

Methods of wax pattern construction

There are three methods for construction of
wax pattern:
1)Direct wax pattern:
-Indicated in case of post crown and inlay
retainer.
-Done and adjusted and carved in the patients
mouth.

2) Indirect wax pattern:

-Indicated in all types of retainers.
-Done on the die and working cast.

3)Indirect-direct wax pattern:

The wax pattern is constructed on the die and
then the margins are refined and rechecked
in the patient mouth.

Steps of wax pattern construction

(indirect method)
1-lubricate the die by any separating medium.
2-using inverted cone bur, a circumferential
groove might be cut around the die, 0.3 mm
below the preparation margin.
N.B. this process is called Ditching of the die
it act as:

a) A guide in carving the wax pattern.

b) Checking the seating of the crown on the die.
c) Finishing of the cast crown at the margin.
3-the wax is softened and placed on the die
increment by increment or by dipping the die in
a container that contains molten wax several
times.

4- after hardening of the wax, carving is carried out

by blunt and slightly hot wax carver. This is
important to minimize the internal stresses inside
the wax
5-the buccal and lingual surfaces: should be carved
to reproduce proper contour and convexity mesio
-distally and occluso -gingivally.
6-the mesial and distal surfaces: should have their
proper contour and contact restored with the
adjacent teeth.

7- the occlusal surface:

a) Its proper carving without any high cusps.
b) Its proper intercuspation with the opposing
teeth.
c) After complete carving and checking,
smoothening of the wax pattern is done by a
piece of silk cloth.
d) The pattern is then sprued and invested as soon
as possible to prevent stress relaxation and
deformity of the pattern

Preparation of the die prior wax

pattern construction
1) Trimming the die:
If the die has a representing free gingiva at a
higher level than the finish line, trimming
away must be done with a stone to define
the margin.

2) Correction of defects:
There are may be small effects in the die
resulting from caries or previous
restorations that are under cut with respect
to the path of withdrawal of the new
restoration. It is convenient to block them
out on the working die with zinc phosphate
cement.

3) Shaping of the die handle:

Shaping of the die handle by using an acrylic
bur, then ditching the die below the finish
line by 0.3mm using inverted cone bur, this
ditching is a circumferential groove act as a
guide during wax pattern construction at the
gingival margin and help also during
finishing of the cast restoration.

4) Marking the margin:

The finish line of the preparation should be colored
with color bright red pencil without any scratches
and to facilitate the carving of the wax at this
margin accurately.
5) Provision of an adequate cement space:
Die spacer ( similar to model airplane paint) is used
to maintain good marginal adaptation. The
produce space (20-40 micron) is necessary to
provide room for the luting agent and permit
complete seating of the restoration during
cementation.

After that the die is thoroughly lubricated with

a water-soluble lubricant to allow the die to
soak in for several minutes, remove the
excess lubricant with gentle stream of
compressed air. The lubricant will reduce
the surface tension and allow the wax to
flow more freely.

The casting wax requirements

1) Has different color than the used die material.
2) Flow readily
3) Easily carved without shipping or flaking
4) Accept addition and carved easily and precisely.
5) Evaporate without leaving any debris or residual
ashes, which can contaminate the produced cast
restoration.
6) Take the fine and sharp details of the pattern and
preserve it till investing without any distortion.

7) Has a minimum rate of stress relaxation

after carving and before investing to prevent
any distortion.
8) Can be burnished and polished.
9) Can compensate part of the metal shrinkage
during its solidification.
10) Has acceptable strength and rigidity after
cooling.

Different methods of wax pattern

construction
1) Dipping method: to develop a thin, uniform
and adapted layer of thin wax on the die.
This is done by dipping the die into wax
that has been thoroughly melted

2) Addition method:
To obtain a bulk of the wax pattern, then
carving is carried out. This is done by
melting the wax and dropping it on the die
using a heated carver until complete bilding
of the pattern, and then carved by sharp
carver. The main drawback of this
technique is due to strain collected from
multiple addition of wax tends to release
with time and subsequently distort the wax
pattern.

Wax instrument
P.K.Thomas wax instrument consist of :
1- wax addition.
2- wax carving.
3- wax burnishing.

P.K.Thomas no.1 and no.2 are wax addition

instruments.
P.K.Thomas no.3 is aburnisher for refining
occlusal anatomy.
P.K.Thomas no.4 and no.5 wax carver.

Wax is added by heating the instrument in the

bunset flame touching it to the wax and
quickly reheating its shank in the flame.
wax flows away from the hottest part of the
instrument, so that if the shank is heated, a
bead of wax will flow off the tip. PKT no.1
instrument is used for large increment, the
smaller no.2 is used for lesser additions.
No.7 A waxing spatula is useful for adding
large amount of wax.

Electric wax instrument

Wax spatula instrument

Internal Surface.
Forming a closely adapted internal
surface is the first step in waxing. The wax
must
reproduce all retention features of the
restoration.

The complete and accurate wax

pattern
A- Proximal surfaces:
1) A proximal surface of the pattern cervical
to the proximal contact should be flat or
slightly concave for interdental papilla.
2) Contact area located more occlusally and
buccally leading to wide lingual embrasure,
While between the first and second molars is
centrally placed

3) Too narrow contact allows fibrous food to

wedge between teeth, while wide contact do
not deflect food.
4) To ensure that the finished restoration with
enough bulk and slight pressure in contact
with the adjacent teeth, without creating an
open contact, grind small amount of stone
from the proximal surface of the adjacent
teeth on the cast of both sides

Buccal and lingual surfaces

1) The surfaces corresponding to surfaces of the
adjacent teeth in the arch.
2) Height of contour lies the cervical 1/3 except on
the lingual surfaces of the mandibular posterior
teeth, which occur at the middle 1/3
3) Height of contour extends 0.5mm. Away from the
level of cementoenamel junction except the
lingual height of lower second premolar (0.75mm)
and lingual of the lower molar (1mm)

4) The line between the base of gingival sulcus and

height of contour described as emergence profile,
which is a straight line to faciliate cleaning by
toothbrush. This creating a space between a)
0.7mm in ceramic restoration b) 0.35mm in
metallic one.
5) Over contouring produces gingival inflammation
As it promotes the accumulation of food debris
and plaque, also hyperplastic changes of the
gingiva may occur, while under contouring may
cause gum recession due to the forced deflection
of food direction or in many cases no significant
changes.

Occlusal surface morphology

1) During centric closure of normal dentition,
lingual cusp of upper and buccal of lower
called functional cusps, which occluded to
fossa or marginal ridges. While other cusps
(non functional) act as rim to prevent over
flow of food and protect the cheek and
tongue away from the functional cusps.

2) Occlusal anatomy and cusps follows the curve of

wilson and anterioposterior curves (curve of spee).
3) Small concavities placed on the distal inclination
of buccal cusp of upper premolars on lateral
movements.
4) Two types of grooves are found, the primary
grooves which represent the union of the lobes and
form the major part of the main pits and groove
pattern, while secondary grooves are to be
characterized by its shallower position and not
concerned with tooth development. The secondary
grooves located at the inclined planes, increase the
cutting and shearing efficiency during mastication.

3) Cervical margin
1) The margin should be checked and corrected.
Some prefer to readapt the margin by burnishing
immediately before investing.
2) The margin is not over extended may affect the
gingival after applying the restoration leading to
gum recession, or under extended which may
cause caries around the margins. The bulge margin
also is biologically not accepted.