Spruing
Dr. Engy Shohdy
Lecturer, Prosthodontics, Future University in Egypt
ILO’s:
• To be familiar with different terminology.
• To recognize the different components of the spruing system
• To know the requirements of the sprue former.
• To know the different types of sprue formers.
• To be familiar with the spruing methods.
• To know the factors that affect the spruing process.
Spruing
Factors
Terminology affecting
spruing
Requirements process
Methods of
of sprue
spruing
former
Types of
sprue
former
Lost wax
technique
Lost Wax Technique
• used since ancient times to
convert wax patterns to cast
metal.
• consists of surrounding the wax
pattern with a mold made of
heat-resistant investment
material.
• eliminating the wax by heating
• then molten metal is introduced
into the mold through a channel
called the sprue way.
Lost Wax Technique
• In dentistry, the resulting
casting must be a highly
accurate reproduction of the
wax pattern in both surface
details and overall
dimensions.
• Small variations in investing
or casting can significantly
affect the quality of the final
restoration.
Spruing
It is the process by which
wax, metal, or plastic
sprue formers are
attached to the wax
pattern, to provide an
entrance or pathway
channel to the mold
space and to serve as a
reservoir of metal during
the casting procedure.
Terminology
• Sprue former: it is a piece of round dental
wax / plastic attached to a wax pattern at
one end and a crucible former at the
other end.
• Sprue way: it is a channel in a mold
created by the elimination of wax or
plastic sprue former.
Terminology
• Sprue: It is the portion of metal casting
that replicates the sprue former.
• Crucible former: it is a round or oval
base to which sprue former is attached
Requirements of sprue former:
1. The sprue former should not leave any residue during burnout.
2. The sprue former must allow the molten wax to escape from the mold.
3. The sprue former must enable the molten metal to flow into the mold with
as little turbulence as possible.
4. The metal within it must remain molten slightly longer than the alloy that
has filled the mold....... to provide a reservoir compensating for the
shrinkage that occurs during solidification of the casting alloy.
Sprue Former
• Definition: it is a piece of round dental wax / plastic
attached to a wax pattern at one end and a crucible former
at the other end.
• Function: it allows the molten alloy to flow inside the mold
in order to reach the pattern areas.
• Materials available are:
A. Wax B. Plastic C. Metal
• Designs available are:
A. Hollow B. Solid
Types of Sprue Former
A. Wax Sprue Former:
• Are preferred for most
castings because they melt
at the same rate as the wax
pattern, thus allowing easy
escape of the molten wax.
Types of Sprue Former
B) Plastic sprue former
Advantages:
• used when casting FPD
because they add rigidity
to the pattern → decrease
distortion.
Types of Sprue Former
B) Plastic sprue former
Disadvantages:
1. Plastic softens at a higher temperature than wax pattern
2. Carbon residues may be left after burning.
3. Plastic has higher expansion before softening than wax
pattern → investment cracking.
4. If plastic didn’t melt at same time as wax → it will block
the escape pathway of wax → wax will boil → erosion of
mold inner surface → rough casting.
To overcome this problem
• Apply a thin layer of wax over the
entire surface of the plastic sprue
former.
• Hollow plastic sprues may be
used.
Types of Sprue Former
C. Metal Sprue Formers
• should be made of non-corroding metal to
avoid possible contamination of the
casting.
• Hollow to increase contact surface area
and strengthen the attachment between
the sprue former and the pattern.
• It is separated from the investment at the
same time the crucible former .
Spruing Methods
A –Direct spruing
• The flow of molten metal is directly from the
casting crucible to the pattern area in the ring.
• Requires less time and effort than indirect
method.
• Used for single units and small multiunit
patterns.
• A round ball of wax is placed between the
pattern and the button to modify the sprue
former and to act as a reservoir to supply
molten metal needed to fill the pattern areas
completely
Disadvantages:
• Suck back porosity that appears as a void at
the junction of the restoration and sprue may
occur.
Spruing Methods
• B- Indirect spruing
• The molten alloy takes an indirect route or
path before it reaches the pattern area.
• In the indirect method, the sprue former is
not attached to the wax pattern directly, but
first to a large diameter horizontal wax rod
called "Runner Bar".
• Then, the second sprue formers attach the
pattern to the runner bar from the other
side.
• Runner bar will act as reservoir to prevent
solidification shrinkage and hence the name
"Reservoir Bar".
Spruing Methods
B- Indirect spruing
Prediction of casting process and the manner the metal
will fill the mold with, is very important since the type of
the alloy will affect the manner the alloy will fill the mold
example;
• Palladium-Silver alloys fills unidirectional.
• Gold Type III alloys fills in a random scattered
fashion.
• Advantages
The main advantage of indirect over direct spruing is
that we can control solidification shrinkage as well as
predictability and reliability of casting process.
Factors Affecting the Spruing Process
1) Diameter
• Large diameter sprue former is recommended because this improves the flow of
molten metal into the mold and ensures a reservoir during solidification.
• 2.5 mm sprue is recommended for molar & metal ceramic patterns.
• 2.0 mm sprue is adequate for premolars
1) Diameter
• In indirect spruing → the reservoir should be equal or larger than the thickest area
of the largest pattern. Example; metal pontics and large molar retainer.
• When using air-pressure casting machines → narrow sprue is indicated to prevent
the molten metal from flowing prematurely into the mold.
2) Location
• The sprue should be attached
to the bulkiest non-critical part
of the pattern away from
margins and occlusal contacts.
e. largest non- functional cusp
is used.
• The point of attachment should
allow a stream of metal to be
directed to all parts of the mold
without having to flow in an
opposite direction to the
casting force
3) Attachment
• The sprue's point of attachment to the pattern should be carefully
smoothed to minimize turbulence.
• The attachment area should not be restricted because necking increases
casting porosity and reduces mold filling
3) Attachment
Constricted spruing (necking) of the sprue former:
• Tapering the sprue former at the attachment rather than flaring
it.
• For low density alloys → it helps to permit the sprue former
to function as a reservoir → decrease suck back porosity.
• For high density alloys → constricted spruing → increase
porosity
• Thus, the greater the metal density, the greater the sprue
former attachment area and its flaring.
4) Length
• With direct spruing, the length of sprue former should be long enough
(5mm) to position the wax pattern outside the heat zone (center of the
ring) and into a cold zone.
• With indirect spruing, the pattern is placed on the connector bar to ensure
the location of wax pattern outside the thermal zone or heat center.
• It should be long enough to leave minimum 6 mm between the wax pattern
and the end of the investment because if ;
✓ Less than 6mm → the investment may fracture during casting.
✓ More than 6mm → the air will not be able to escape during casting
causing back pressure porosity.
5-Orientation of the Wax Pattern
• The sprue must also allow for proper positioning of
the pattern in the ring. This can be crucial because
expansion within the mold is not uniform
• No 90-degree sharp angles between the sprue former
and wax pattern.
• No positioning of the wax pattern in a way that the
molten alloy flows backwards towards the ring
enterance.
• The pattern has to be placed to allow alloy to flow
from areas of large volume to areas of lesser volume
(i.e. from the reservoir towards the margins.)
5) The reservoir
• Whether it is a sprue former of gauge
1, 3 or 6 or a round ball, it should be
placed in the heat center of the ring.
• It should be the largest part of the
sprue system.
• This will permit the reservoir to
remain molten until the patterns
complete the solidification process.
Venting
• Small auxiliary sprues or vents have been
recommended to improve the casting of
thin patterns.
Function:
• Help gases escape during casting
• ensure that solidification begins in critical
areas by acting as a heat sink
Crucible Former
• Crucible former: it is a round or
oval base to which sprue former is
attached
• It is usually made of rubber.
• It serves as a base for the casting
ring during investing.
• It is tall to allow the use of a short
sprue and also enables the wax
pattern to be positioned near the
end of the casting ring
Casting Ring