Casting

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Within this department, we cast metal frameworks from cobalt-chromium alloys. These frameworks can then be used as the base for metal-ceramic prostheses. Additionally, the production of many types of removable and skeletal dentures requires the prior creation of a metal framework.

You can learn more about the practical use of cast frameworks on the pages of the respective departments.

A cast framework does not necessarily have to be an intermediate step. A “fully anatomical” cast prosthesis—without any covering—can be a way to significantly reduce the cost and speed up the prosthesis production process.

However, such prostheses are highly visible in the patient’s mouth and are therefore not particularly popular.

The first step in creating a cast prosthesis is to create a wax model that perfectly replicates the shape of the future framework. This model can be created manually by a technician or can be milled in our digital milling center using the CORiTEC 150i PRO. Milling the wax model is much more precise and faster than the alternative method.

  • CORiTEC 150i PRO

    The milling center is designed for high-precision processing of dental prostheses. It features 5-axis technology, allowing for the production of complex restorations from various materials. Its compact size and automatic tool changes ensure ease of use and high productivity. We strive for high quality and precision in our products, making the CORiTEC 150i PRO ideally suited for our dental laboratory.

    CORiTEC 150i PRO

The next step involves attaching the sprue system to the wax model. The sprue system consists of wax pins that simulate the future pathways for the molten metal to flow into the framework mold. One of the cross wax beams—the collector—must be thick enough.

The problem is that metal shrinks in size as it cools. The collector must contain enough metal reserve to compensate for the volume loss in the prosthesis. An electric spatula—a tool for locally melting wax—is actively used in assembling the sprue system.

Next, the wax model along with the sprue system is attached to a silicone mold and filled with refractory investment material. The top of the sprue system is attached to the funnel-shaped indentation of the mold. After the material solidifies, it is placed in a muffle furnace. At high temperatures, the wax completely burns out, leaving us a mold with cavities inside.

The metal is poured into the mold in the Ducatron Quattro casting machine. To prevent the metal from solidifying in the sprue system, the mold is placed into the machine preheated. The metal, heated by the machine’s inductor to a liquid state, penetrates the mold under centrifugal force, filling all the cavities.

You can read more about the basic principles of the high-tech operation of the casting machine on the equipment’s respective page.

  • Ugin Dentaire Ducatron Quattro

    The centrifugal induction casting machine is our main tool for working with cobalt-chromium alloys. The machine’s inductor melts the metal, creating chaotic oscillations in the alloy at the molecular level. The heating is very localized. The inductor coil is water-cooled. The molten metal flows into the mold under the influence of centrifugal force generated by the rapid rotation of the structure holding the crucible and mold.

    Ugin Dentaire Ducatron Quattro

After the metal has been cast in the machine, we wait for the mold to cool down gradually. Then, the mold is broken, and the sprue system is cut off from the finished prosthesis.

Technicians working in this department