Removable dentures

The process of creating a removable denture begins with taking a dental impression from the patient. After the impression is sent to the laboratory, an individual tray for the next impression will be prepared. During the second impression, the dentist records the patient’s bite using a silicone bite block or Futar D. Using wax to record the bite is an outdated and unreliable technique. We strongly recommend applying reference lines to the bite block.

However, if the patient requires a partial removable denture, the bite can be recorded during the first visit. This saves the patient time and significantly reduces the manufacturing period. Thanks to this approach, we offer record-breaking production times for removable dentures!

The fabrication of dentures using the Ivoclar BPS system takes up to 5 days, nylon dentures for allergy sufferers (Deflex) up to 6 days, and partial removable dentures with Bredent Bio Dentaplast clasps up to 7 days.

We provide the option to send the layout of tooth set options to the dentist, allowing the patient to express their wishes and preferences regarding tooth shape and the dentist to advise on the color shade. In manufacturing removable dentures, we exclusively use Ivoclar Ivocryl teeth!

At the next stage, the final dental impression is cast in plaster. The surface of the model is covered with a thin wax sheet, and the modeling of the denture begins. Once the fitting surfaces for the gum and palate are wax-modeled, a thin wax rim is added to the model, where the teeth are mounted.

During the modeling process, we use the Ivoclar Gnathometer “M” with the patient’s individual parameters. We also use the Ivoclar Stratos 300 articulator, which provides much greater flexibility in modeling than a traditional occluder. Thanks to the articulator, the technician can account for lateral jaw movements and make more precise markings.

If the denture is partially removable and attaches to natural teeth using clasps, the pre-made clasps are fixed in wax during the modeling stage. We manufacture cast clasps from cobalt-chromium alloys in the respective department and elastic clasps from Bredent Bio Dentaplast. Bio Dentaplast is pre-pressed in a Deflex injector, following a process similar to removable denture fabrication (wax modeling, plaster casting, pressing).

  • Casting

    Precise molding of metal frameworks for fixed and removable prostheses made of cobalt-chrome alloys.

    : Casting
    Casting

Often, a cast reinforcement is inserted into the palatal section of an upper complete denture to significantly increase the strength and wear resistance of the plastic. If reinforcement is used, it is embedded into the wax model of the palate at the same stage as the clasps.

After completing the above process, the model with the wax setup and mounted clasps (in the case of a partial denture) is sent to the dentist for a trial fitting. Once the setup is returned, the technician performs detailed modeling of the “pink aesthetics” – the decorative artificial gum. For work with the IvoBase or Deflex system, a pre-made wax sprue system is attached to the final wax model.

At the next production stage, the plaster model with the wax setup is encased in additional plaster within a flask. This results in a closed plaster mold, with its internal cavities entirely filled with wax. Once the mold has set, the cavities are treated with hot steam or heated in another way to completely remove the wax.

Deflex material is inconvenient for manual adjustment, making it challenging for the dentist to fit the denture in the patient’s presence. Therefore, after producing the removable denture, it must be tried on in the laboratory. For this, a plaster model of the jaw is needed, but the original model has already been used as part of the plaster mold. Consequently, when working with the Deflex technology, we always create a duplicate plaster model.

Next, we prepare the mold for the pressing process. The internal cavity surfaces must be coated with a separator material. For the IvoBase technology, Ivoclar Separation Fluid is used, and for Deflex, a photolacquer is applied.

If the denture has reinforcement, it must be fixed in the mold so it does not shift during wax removal. Small pieces of already hardened plastic, from which dentures are made, are used for this purpose. These pieces are attached to the wax model of the palate before the model is encased.

The finished mold is placed in an injector: the IvoBase Injector for the BPS technology or the Deflex injector for other cases. Deflex material is sometimes replaced with Vertex, which offers slightly greater flexibility. The components of the liquid material, which will be pressed into the mold, are mixed and preheated. Once all components are heated, the injection process begins. During this process, the material fills the mold cavities under the influence of heat and pressure and begins to harden.

  • Ivoclar IvoBase Injector

    An injection system for the automatic production of polymethyl methacrylate (PMMA) prostheses. It provides precise dosing and even material distribution, ensuring high quality and durability of the products. Additionally, the system features an intuitive interface and programmable modes, simplifying the work process and improving efficiency, and is fully suitable for creating denture bases and orthodontic structures.

    Ivoclar IvoBase Injector
  • Deflex Integra TOUCH

    High-tech equipment for precise milling and processing of dental constructions. It is equipped with a touch screen for easy control, supports work with various materials, and offers high precision and processing speed. It also has an automatic calibration system that ensures consistent quality during prolonged use.

    Deflex Integra TOUCH

When working with Ivoclar Triplex plastic, the mold is divided into two parts, and the technician manually fills the cavities with pre-prepared plastic in a pliable state, replacing the injection process.

Once the pressing process is complete, the mold is removed from the injection device and allowed to cool naturally to minimize the impact of shrinkage on the resulting denture. The plaster mold is then removed from the flask, and the plaster is cleaned off the denture.

In the final stage of production, the technician trims the sprue system and polishes the denture. If necessary, manual adjustments are made.

Removable dentures do not necessarily need to rely on adhesion or support from other teeth. We can fabricate hybrid removable dentures – dentures that attach to implants. More information on types and methods of implant-supported prosthetics can be found on the respective department’s page.

When one or more teeth are extracted, it may be necessary to fit a temporary partial removable denture during the manufacturing period of a personalized removable denture. Such dentures are called immediate dentures.