PRESENTED BY –
D R . YA D N E S H D O N D U L K A R
1 ST M D S
CONTENTS :-
INTRODUCTION
HISTORY
INDICATIONS
CONTRAINDICATIONS
MATERIALS FOR CAST RESTORATION
CASTING PROCEDURES
CASTING DEFECTS
REFRENCES
INTRODUCTION
• Taggart introduced cast gold restoration technique and changed
the concept of restorative dentistry.
(Marzouk)
HISTORY
Ref-Evolution of restorative dentistry from past to present.( Indian journal of dental sciences 2017 vol-9)
• 1884 Agulihon de Saran used 24k gold for inlay
Marzouk
• Restoration of endodontically treated tooth
Marzouk
• Partially subgingival restorations
• Cracked teeth
Marzouk
• Correction of occlusal plane
Marzouk
CONTRAINDICATIONS
• Occlusal disharmony
• Dissimilar metals
• Esthetics
• Small restoration
Marzouk
MATERIALS FOR CAST RESTORATION
Marzouk
Mouth preparation prior to cast restorations
• Control of plaque
• Control of caries
• Proper foundation
• Occlusal equilibration
Marzouk
Casting procedure
Steps in casting
Wax pattern
Spruing
Investing
Burnout
Casting
Recover of casting
Finishing &polishing
Wax pattern
Instruments for waxing technique were introduced by Dr. Peter K Thomas hence
known as PKT instruments.
Ref- Waxing Techniques to Develop Proper Occlusal Morphology in Different Occlusal Schemes (The journal
of Indian prosthodontic society Dec 2011)
Methods of wax pattern fabrication
1. By carving
2. Incremental built up
3. Direct built up
1. Cusps with their tips are build in exact same location & checked
in static and dynamic occlusal relation.
2. Triangular ridges of cusps are added & checked for any
deficiencies or interference.
3.Marginal ridges are built up &checked.
4. Facial, lingual & proximal contour & anatomy is
established and checked.
5.Fossae & grooves are completed & checked.
6. Pattern is marginated & surface is polished.
C) Direct wax pattern
2. inlay wax stick is softened at tip and gently kneaded & inserted in
5. Pattern is replaced after lubricating it for second time and deficient contouring can be
adjusted.
7. While holding the pattern with apical pressure using a small burnisher & is polished
discrepancies.
D) Anatomic core wax pattern
1.Before preparing teeth for cast, desired shape of future restoration is built
with hard wax, all mandibular movements are made and wax is adapted
accordingly.
2. Pick up impression is made with impression plaster above height of contour,
resulting impression serves as anatomic core.
3. Teeth preparation , impression & die preparation is carried out, anatomic
core is verified on working model.
4. One die is filled at a time with molten wax & lubricated anatomic core is
pressed down under pressure to determined position until wax solidifies.
5. Anatomic core is removed & fine adjustments are done. Other patterns are
fabricated in same manner.
Spruing and surface treatment
Sprue: the mould channel through which molten metal or ceramic flows into the
Sprue former: A wax, plastic or metal pattern used to form the channel or
channels allowing molten metal to flow into a mould to make a casting (GPT 8 edition).
Factors determining sprue design
If the pattern has thin area between sprue and periphery, two or more
sprues are indicated.
Angulation of sprue
Sprue is never directed 90° to flat portion of wax pattern. It should always
directed at 45° to these details.
• Smooth
• Flared
• Uninterrupted
Reservoir
It is made by adding wax around sprue former 1-2 mm from the pattern to create
area in
Mould with dimensions more than the thickest portion of the pattern.
Indicated when sprue is thin and long.
Venting
Asbestos paper
Cellulose liner
Aluminium silicate ceramic liner
Crucible former
C) Silicate bonded is used for casting RPD with base metal alloy
TYPES OF EXPANSIONS
Occasionally it is important to alter the size of the mould depending upon the size of
&metal used for casting .
1) Two liners allow greater setting and thermal expansion than one liner.
2) Varying l/p ratio – lower l/p ratio – greater expansion; greater l/p ratio – lower
expansion.
4) Controlled water added techniques – here in a flexible rubber ring, pattern is invested,
allowed to set specified amount of water is added on the surface of set investment as
room temperature depending upon the expansion required.
Steps in investment
• Gypsum bonded is heated for 500° C for hygroscopic technique or 700 ° C for
thermal expansion technique.
• slowly heated to 650-700 °C in 60 min & held for 15-30 min at upper temperature
by placing mold in furnace at 315 ° C for 30 min followed by very rapid heating to
• Few investments can be directly placed at final burnout temperature, held for 30
min an cast.
Phosphate bonded investment –
• Investment is directly placed at the top temperature, held for 20-30 min and
then casted
CASTING
Casting is defined as something that has been cast in a mould, an object formed
by the solidification of a fluid that has been poured or, injected into a mould.
7TH edtion GTP
• Clay crucible
• Carbon crucible
• Quartz crucible
• Zirconia-alumina
CASTING MACHINE
A) TORCH MELTING / CENTRIFUGAL CASTING MACHINE
1. No combustion zone 1 2 3 4
2. Combustion zone
3. Reducing zone
4. Oxidizing zone
B) Electrical resistance-heated casting machine
• After gold alloys casting has solidified, ring is removed & quenched in water.
• Casting using Phosphate bonded investment are not quenched but benched
cooled
C. After seating the casting hand burnishing of marginal metal using ball or
C
D. Remaining sprue is removed using heatless stone or carborundum disk.
I. Proximal grooves and other inaccessible areas are polished using rubber point.
J. Applying Tripoli/ Buffing bar compound to occlusal surface using bristle disk.
K. Applying Tripoli/ Buffing bar compound to proximal surface using felt wheel.
CLASSIFICATION OF DEFECTS
1) According to Phillips
• Distortion
• Surface roughness and irregularities
• Porosity
• Incomplete casting
2) According to location
• Internal
• external
A) Distortion
Any distortion of casting is probably related to distortion of wax pattern
Causes-
• As investment hardens around the pattern
• If the thickness of the wax is decreased
• More setting expansion more is the distortion
Prevention-
• Proper manipulation and handling of the wax pattern
• Investing as early as possible.
B) Roughness , Irregularities and Discolouration
Surface irregularities are isolated imperfections such as nodules, that are not
characteristic of the entire surface area.
Causes-
• Improper technique.
• Air bubbles
• Water films
• Prolonged heating
• Casting pressure
• Pattern position
• Carbon inclusions
C) Porosity
Classification of porosity
Site-
• Near the sprue-casting junction
Causes-
• Premature termination of molten metal during solidification.
• If sprue freezes in its cross-section before feeding of molten metal is completed.
Minimization
• By attaching one or more small sprues at most distant from main sprue
attachment.
Suck-back porosity
Causes-
The entering metal impinges on to the mold surface & creates a higher localized
mould temperature in this region that is called as Hot spot.
A Hotspot may retain a localized pool of molten metal after other areas of casting
have solidified.
This in turn creates a shrinkage void that is called as Suck Back porosity
Minimization-
Flaring the point of sprue attachment
Causes-
• Solidification is too rapid for microvoids to segregate to the liquid pool.
• Rapid solidification if the mold or casting temperature is too low
Minimization-
• By increasing the melt temperature.
• By increasing the mold temperature.
Pinhole & gas inclusion porosity
Causes-
• Entrapment of gas during solidification
• Dislodgement of the particles of investment during casting
Minimization-
• Preheating the gold alloy in graphite crucible
• Adjusting the torch flame during melting .
Subsurface porosity
Causes-
• simultaneous nucleation of gas & solid grain
Minimization-
• By controlling the rate at which molten meatal enters mould .
Site-
Cavity surface of crown or MOD casting.
Causes-
• Inability of the air in the mold to escape through the pores of the investment.
• Pressure gradient that displaces the air pocket towards end of the investment.
• Casting temperature or mold temperature is low.
• Dense modern investment material.
Partially complete casting or no casting has been found due to incomplete filling of
mold by molten metal
Causes-
• Insufficient venting of the mold
• High viscosity of fused metal
• Incomplete elimination of wax
1. Evolution of restorative dentistry from past to present.( Indian journal of dental sciences 2017 vol-9)
3. Marzouk
7. Waxing Techniques to Develop Proper Occlusal Morphology in Different Occlusal Schemes (The