Design Transfer
Before the actual construction can begin, the design must be placed on the master
cast.
Since each lab may have their own method of design construction the best results is
achieved when the technician transfers the design from the diagnostic cast.
Examine the master casts to determine acceptability. If acceptable, the casts
should be examined for nodules that must be removed. If large nodules appear in
critical areas such as rest preparations, new master casts should be requested.

The design on the master cast should be the same as the design on the diagnostic
cast.
B) Cast Preparation
Before the blockout is done the cast is beaded that is, the outline of major
connector will be scraped into the master cast.

This will result in a bead line on the finished maxillary casting that will ensure
positive contact against palatal tissues reducing the packing below the major
connector.
The bead line should be 3-4 mm away from the gingival margin.
The master cast should be treated with a model spray that protects the design
thought the blockout and duplication.

C) Blockout and Duplication

Preparing the casts for duplication. Casts are blocked out to eliminate undercut
areas on the master cast that will be crossed by rigid parts of the partial
denture. Additional areas to be blocked out , which are eliminated for convenience,
include
1. Ledges on which clasp patterns will be placed
2. Beneath connectors to avoid soft tissues impingement
3. To provide for later attachment of the denture base to the framework
Types of blockout may be classified as:
1. Parallel
2. Shaped (ledging)
3. Arbitrary
4. Relief
Paralleling blockout
This blockout should be parallel to the path of insertion and removal. Parallel
blockout extends from the survey line to the gingiva.

2) Shaped blockout or ledging
Shaped blockout or ledging is used on buccal or lingual surfaces to facilitate
accurate placement of plastic or wax patterns for clasp arms.
The blockout wax may be placed in the undercut and trimmed flush with the survey
line using the wax trimmer.

Ledging may be done only in the area of the tip of the clasp; this is the most
desirable method.
It permits more flexibility in the waxing procedure, and, if the refractory cast is
well made, there is no difficulty in placing the bracing portion of the clasp.

Ledging for Circlet Clasp (pic left), Ledging for Bar type Clasp (pic right)
3) Arbitrary blockout
Arbitrary blockout is used in less critical areas to prevent the encroachment of
metal on the soft tissues and to critical withdrawal of the blocked out cast from
the duplicating material.
It is used for all gingival crevices, spaces between the teeth when they are not in
the design, for soft tissue undercuts below areas involved in the design of the
framework, and in the tooth or tissue undercuts not involved in the design but that
would complicate the duplication procedure.
Gingival crevices (pic left), Gross undercuts below the design (pic right)
4) Relief blockout
Relief is used to create a space between the framework and the cast or soft tissue.
Relief is also used beneath framework extensions, in edentulous area to provide for
attachment of denture bases, and to form internal finish lines.
Relief is usually used beneath lingual bars and in other area where major
connectors will contact thin soft tissue such as maxillary and mandibular tori.
D) Duplication and Refractory Casts
The purpose of duplication in stone of the original or corrected master cast is to
preserve the original.
One use of such cast is for fitting the removable partial denture framework without
danger of fracture or abrading the surface of the original master cast.
Another reason to duplicate a cast is to allow formation of an investment framework
fabrication.
Duplicating materials commonly used are reversible , irreversible hydrocolloids and
silicone materials.
(From left) Duplicating materials (agar), Automated Machine Agar Dispenser,
Duplicating Flasks
Silicone Duplicating Materials
Reversible hydrocolloids (agar)
• Reversible hydrocolloid (agar) is used most often to make the mold for
duplication.
• Agar hydrocolloid is prepared by grinding or chopping the colloid into
small pieces and heating it until it liquefies at 212°F (100°C).
• The melted colloid can be stored for a few hours in a hydrocolloid
storage unit at 135° to 140°F.
• Since this material is heat reversible, it may be reused a number of
times to make a duplicate casts.
• After each used, it should be washed under cool water to remove all
traces of stone and investment, cut into small pieces, and stored in a closed
container to prevent loss of water.
Silicone materials (duplicating method)
After duplicating, the casts are placed in a drying oven at a temperature between
180° and 200°F (82° and 93.5°C) for a period of 2 to 3 hours, depending on the
amount of material in the oven.
Remove the casts from the oven one at a time, and spray them completely (top and
bottom) while warm.
Master Cast and Refractory Cast
E) Waxing and Spruing
After the master cast is duplicated to make a refractory cast, it is necessary to
transfer the design to the refractory cast and complete the wax pattern. Wax and
plastic patterns are available in variety of shapes and sizes.
Waxing the framework have different methods of doing:
a) Freehand – A slow method of waxing with no control of uniformity
b) Wax patterns – Faster than freehand, has more control of uniformity than
freehand. Do not compress patternswith very much pressure or the pattern will
distort.
c) Plastic patterns – Excellent and fast method of waxing.
d) Combination – Combines the best qualities of freehand, wax patterns and plastic
patterns
How to do the waxing technique?
1. A sheet thickness of casting wax or plastic is cut to approximately outline of
the major connector.