CONTENT

 Definition
 Design Consideration
 Types
 Related Studies
 Soldering, brazing & welding
 Soldering flux, antiflux & investment
 Heat source
 Soldering techniques

DEFINITION
Connector in fixed prosthodontics, the portion of a fixed partial denture that unites the
retainer(s) and pontic(s).

GPT (10)

CLASSIFICATION
 RIGID CONNECTOR
A) Cast connector shaped in wax
B) Soldered connector-intermediate metal alloy
C) Welded connector-joining with heat
D) Loop connector

 NON RIGID CONNECTOR

A) Dovetail or key-key ways
B) Split pontic
C ) Cross-pin and wing

DESIGN CONSIDERATION :

 Hygiene considerations
 Biologic considerations
 Mechanical consideration
 Aesthetic considerations

Hygiene considerations

Mesio-distally - smooth transition.

Tissue surface - highly polished and curved facio-lingually to facilitate cleansing.
The connectors should occupy the normal anatomic inter-proximal contact areas.
Not be bulky inciso-cervically, to allow efficient plaque control measures.
Biologic considerations
The pulp size and crown height are the limiting factors for the placement of non-rigid
connectors as the pre-fabricated patterns require the preparation of box in the retainers.

Mechanical consideration
The bucco-lingual cross section - elliptical shape.
It is the strongest shape for the connection if the major axis of the ellipse parallels the
direction of the applied force.
This might not be possible to achieve in all cases due to anatomical factors.
Due to space constraints, most of the connectors have their greatest dimension perpendicular
to the direction of the applied force which thereby results in a weak connection.

Aesthetic considerations

Large inappropriately designed connectors will lead to metal exposure and compromised
aesthetics.
Connectors should occupy the normal anatomic inter-proximal contact areas.
Slight lingual placement - improve the aesthetics.
Cross-sectional views through fixed dental prosthesis connectors. A, Maxillary anterior view.
B, Maxillary posterior view.
C, Mandibular posterior view.
Note the convexity of the gingival surface of the connectors. To prevent excessive display of
metal, anterior connectors should be placed toward the lingual embrasure.

Rigid Connectors:
Are immovable attachments between the pontic and retainer.
Example - Solder joints.

Non-rigid connectors:
Are movable attachments with a Key-keyway mechanism.
Example - Precision attachments (stress breakers).
RIGID CONNECTORS:

Used when the entire load on the pontic is to be transferred directly to the abutments.

A rigid connection can be made by casting as part of a multiunit wax pattern or by soldering.

INDICATIONS:
1) They are used to unite retainers and pontics in a fixed - fixed partial denture.
2) These connectors are used when the entire load on the pontic is to be transfered directly to
the abutments.

CONTRAINDICATIONS:
1) In cases where existing diastema is to be maintained
2) In case of tilted abutments
3) In abutments with differing long axis
4) In long span bridges

ADVANTAGES:
1) Easy to fabricate
2) Less armamentarium required
3) Can easily be fabricated by laboratory people.
4) Less time consuming

TYPES OF RIGID CONNECTORS

1) Cast connectors:

Shaped in wax as part of a multiunit wax pattern.

Cast connectors are convenient and minimize the laboratory fabrication.
Tend to create more problems than do soldered connectors, especially as pattern
complexity increases.
2) Soldered connectors

a. Connectors to be soldered are waxed to final shape but are then

b. Sectioned with a thin ribbon saw
c. Casted separately & joined.
d. This allows accurate soldering with minimum of distortion.

Soldered connectors involve the use of an intermediate metal alloy whose melting
temperature is lower than that of the parent metal the parts being joined.

Dirt or surface oxide on the connector surfaces can reduce wetting and impede successful
soldering.

Molten solder will flow toward the location where the temperature is highest.

A, A ribbon saw is used to section the wax pattern. B, The sectioned surface should be flat
and located far enough incisally and lingually to allow adequate hygiene and esthetics of the
completed partial fixed dental prosthesis(FDP). C, A three-unit FDP after sectioning. D,
Framework ready for porcelain application. Note the uniform gap width (arrow).

Soldering gap width:

An even soldering gap of about 0.25mm is recommended.
As gap width increases soldering accuracy decreases.
Extremely small gap width can prevent proper solder flow and lead to an incomplete or weak
joint.
Indications :
Used when an existing diastema is to be maintained.
Consists of a loop on the lingual aspect of the prosthesis that connects adjacent retainer or
pontics.
May be cast from a circular sprue wax or shaped with platinum-gold-palladium alloy.

Disadvantage :
Plaque control is a problem.
NON- RIGID CONNECTOR
The design of nonrigid connectors that are incorporated in the wax pattern stage consists of :

A mortise ( “female” component) : prepared within the contours of distal surface of the
anterior retainer.
A tenon (“male” component) : attached to the pontic.
The mortise can be prepared freehand in the wax pattern or with a precision milling machine.

Indications for non rigid connectors :

Relieve stress / act as stress breaker

To accommodate malaligned fixed partial denture abutments

DOVETAIL (KEY-KEYWAY) OR TENON-MORTISE TYPE CONNECTORS

INDICATIONS:
1) This technique is best suited for releiving stress at midspan on long pontics. Consists of a
mortise (female) prepared within the contour of the retainer and a tenon (male) attached to
the pontic.
2 ) In periodontically weakened abutments
3) In cases of long fixed partial dentures.
4) In cases of heavy occlusal forces.

ADVANTAGES:
1) Relieve stress on abutments.
3) Allows for easy repair. In case of fracture, not the whole assembly has to be repaired only
the defective segment has to be removed
and repaired.
2)Acts as a splint of periodontically weakened teeth.

CONTRAINDICATIONS:
1)Cannot be used in short abutments
2)Medically compromised patients.
3)Patients not willing for extensive tooth preprations

DISADVANTAGES:
1)Time consuming
2)Cost factor
3)Require extensive tooth prepration
PATTERN FOR FABRICATION OF TENON MORTISE CONNECTOR
1. The wax pattern for the retainer on the pier abutment is fabricated.
2. It must be parallel the path of withdrawal of the other retainer.
3. Place the working cast, with the wax pattern seated on the table of a surveyor.
4. Assemble the key and key way portion of the connector, and lock the mandrel that
extends from the top of the key portion of the pattern into the vertical spindle of the
surveying instrument.
5. Manipulate the surveyor table until the mandrel and attachments are parallel with the
path of insertion of the distal preparation.
6. Remove the key portion and complete the middle retainer wax pattern by blending the
distal surface with the key way.
7. The pattern is then invested, burned out and cast.
8. Place the casting on the working cast.

SPLIT PONTIC
Indication :
This is an attachment that is placed within the pontic.
It is particularly useful in tilted abutment cases, where the conventional dovetail would
necessitate the drastic preparation in the distal aspect of the pier abutment.
• Used in pier abutments.

ADVANTAGES :
1) When problem occurs only the affected segment can be removed and repaired or remade,
no need to remove the whole assembly.
2) Stresses that are to be applied are evenly distributed.
3) Allows some degree of movement in function and hence protects the abutment
overloading.
4) Also act as a splint.

DISADVANTAGES :
1) More time consuming
2) Cost factor.

FABRICATION OF WAX PATTERN FOR SPLIT PONTIC

1. The wax pattern for the anterior three-unit segment is fabricated first, with the distal
arm attached to the pier relations.
2. The underside of the arm is shaped like the tissue containity area of a pontic
A surveyor is used to make sure the segment must align with the distal abutment
preparation.
3. Invest, burnout and cast the mesial third and a half unit segment.
4. After preliminary finishing, seat the cast segment on the working cast.
 5. Wax the distal retainers at distal occlusal two-third of the pontic pattern.
Cement the mesial segment first followed by distal segment.

CROSS PIN AND WING CONNECTOR

INDICATIONS:
1)The design will be primarily used to accommodate the abutment teeth with disparate long
axis.
2)Used in case of tilted molars.

FABRICATION OF CONNECTOR
1. The working elements of a two-piece pontic system allows the two segments, to be
rigidly fixed after the retainer have been cemented on their respective abutment
preparations.
2. The path of insertion of each tooth preparation is made to parallel the long axis of
each tooth.
3. Attach a vertical wing, cut out of a piece of base palate wax, to the mesial surface of
the distal retainer wax pattern, the wing should parallel the path of insertion of the
mesial abutment preparation.
4. Invest, burnout and seat the distal retainer. Seal it on the cast and drill 0.7 mm while
through the wing with a twist drill.
5. Plane 0.7 mm lead pencil through the hole and build the wax pattern around the lead
and the wing : Place 0.7 lead pencil in the pontic during investing so that the hole will
be there in the pontic.
6. Assemble the two parts of the fixed partial denture on the working cast, use a reamer
and smoothen the hole in the pontic.
7. Fabricate a pin of the same alloy used for fixed partial denture.
8. It must be long enough to extend all the wax throughout the pontic cone assembly
9. Try the pins for fit on the components on the cast.
10. Cement the retainer with the wing first followed by the retainer pontic segment.
 11. Seat the pin in the hole with a punch and mallett. Remove any excess length both
facially and lingually.

ADVANTAGES:
1) No need to remove the whole assembly if required.
2) Stress distribution
3) Reduces the amount of force on abutments.

DISADVANTAGES:
1) Time factor
2) Additional laboratory steps required for pin fabrication.
3) Technique sensitive.

AN ALTERNATIVE ORIENTATION OF NONRIGID CONNECTORS IN FIXED

PARTIAL DENTURES
Moulding MB., Holland GA., & Sulik WD. (1992)

Described an alternative orientation of non rigid connectors in fixed partial dentures to

overcome space limitations which may require over reduction of the preparation or over
contouring of the retainer to place to keyway within he retainer wall
With this alternative orientation the key is attached to the distal surface of the mesial retainer
in a dual abutment fixed partial dentures, and the keyway is incorporated in the mesial
surface of the pontic.

Advantages :

(1) Conventional tooth abutment preparations with less reduction.

(2) Suitable axial contours,
(3) Simplified angulation and placement of the nonrigid connector with mesially inclined
posterior abutment .
(4) Improved esthetics with porcelain.
OTHER RELATED STUDIES

1) Automated Remodelling of Connectors in Fixed Partial Dentures : Hassen Jemaa ,

Michael Eisenburger and Andreas Greuling (2023)

This study aimed to develop an approach for parametric remodelling of the connectors
dimension of FPDs and to study the influence of connector design on the stress
distribution within a 4-unit FPD.

The results indicate that cross-sectional area has a large influence on the resulting
stresses, depending on the geometric reduction from the occlusal side had the greatest
effect on compressive stresses (minimum principal stresses), while a reduction from
the gingival side showed the greatest effect on tensile stresses (maximum principal
stresses). The tensile stresses become maximal at the gingival side of the middle
connector.

(Jemaa H, Eisenburger M, Greuling A. Automated Remodelling of Connectors in

Fixed Partial Dentures. Dent J (Basel). 2023 Oct 27;11(11):252)

2) Effect of connector design on the fracture resistance of all-ceramic fixed partial

dentures : Won-suck Oh, DDS, MS,a and Kenneth J. Anusavice, DMD, PhDb (2002)

With the use of a standardized silicone mold, 40 three-unit FPD wax patterns were
fabricated with the same dimensions and divided into 4 groups of 10 specimens per
group.
Each pattern was modified at the connector areas of the occlusal embrasure (OE) and
the gingival embrasure (GE); 2 wax carvers with radii of curvature at their tips of 0.90
mm and 0.25 mm were used.
The dimensions of the connectors were standardized with an electronic caliper to 4 ±
0.12 mm in height and 5 ± 0.13 mm in width. Connector designs were as follows:
Design I: OE and GE 0.90 mm; Design II: OE 0.90 mm and GE 0.25 mm; Design III:
OE 0.25 mm and GE 0.90 mm; and Design IV (control): OE and GE 0.25 mm.

Results revealed a significant difference between the mean failure loads of different
connector designs.
The mean loads to failure for Designs I and III were significantly higher than those for
Designs II and IV.
Within the limitations of this study and for the experimental ceramic tested, as the
radius at the gingival embrasure increased from 0.25 to 0.90 mm, the mean failure load
increased by 140%. The radius of curvature at the occlusal embrasure had only a minor
effect on the fracture susceptibility of 3- unit FPDs.
(Oh, Won-Suck & Anusavice, Kenneth. Effect of connector design on the fracture resistance
of all-ceramic fixed partial dentures. The Journal of prosthetic dentistry. 2002. 87. 536-42)

3) Effects of Prosthetic Material and Framework Design on Stress Distribution in Dental

Implants and Peripheral Bone: A Three-Dimensional Finite Element Analysis: Hakan Arinc
(2018)

The study was conducted with a mandibular implant-supported fixed dental prosthesis with
different prosthetic materials [cobalt-chromium-supported ceramic (C), zirconia-supported
ceramic (Z), and zirconia-reinforced polymethyl methacrylate (ZRPMMA)-supported resin
(ZP)] and different connector widths (2, 3, and 4 mm) within the framework were used to
evaluate stress via FEA under oblique loading conditions
Minimum stress values were observed in the model with a 2-mm connector width for C and
ZP. The models with 3-mm and 4-mm connector widths showed higher stress values than the
model with a 2-mm connector width for C (48–50%) and ZP (50–52%).

(Arinc H. Effects of Prosthetic Material and Framework Design on Stress Distribution in

Dental Implants and Peripheral Bone: A Three-Dimensional Finite Element Analysis. Med
Sci Monit. 2018 Jun 22;24:4279-428.)
4) Mechanical comparison of milled fiber-reinforced resin composite and Co-Cr frameworks
with different connector cross-sectional geometries: An in vitro study: Freitas BN, Tonin
BSH, Zaparolli D et al. (2023)

This study compared the effect of using milled fiber-reinforced resin composite and Co-Cr
(milled wax and lost-wax technique) frameworks for 4-unit implant-supported partial fixed
dental prostheses; and also, evaluated the influence of the connector's cross-sectional
geometries on the mechanical behavior.

Three groups of milled fiber-reinforced resin composite for 4-unit implant-supported

frameworks (n = 10) with three connectors geometries (round, square, or trapezoid).
Results suggest that trapezoid connectors mechanical behavior did not perform well
compared to round or square geometries.

(Freitas BN,Tonin BS, Danilo Zaparolli D et al.,Mechanical comparison of milled fiber-

reinforced resin composite and Co–Cr frameworks with different connector cross-sectional
geometries: An in vitro study. Journal of the Mechanical Behavior of Biomedical
Materials.2023.105759)
Soldering Brazing & Welding

SOLDERING : In soldering metal parts are joined together by melting a filler particle
between them at a temperature below the solidus temperature of metal being joined and
below 4500.

BRAZING : In brazing metal parts are joined together by melting a filler metal between them
at a temperature below the solidus temperature of the metal being joined and above 4500.

WELDING : It is the process during which a portion of the metal being joined is melted and
flowed together.

According to Hardness :
Soft solders : eg. Lead tin alloys with a low melting point.
Hard solders : eg. Dental gold solders, silver solders.

According to Technique :
Free hand soldering ; used in assembling orthodontic and other assemblies.
Investment soldering ; used in bridges and restoration.

PRECERAMIC SOLDERS : high fusing alloys, fusing only slightly beneath the softening
point of the parent alloy to be jointed.
Recommended presolder melting range : 1110 - 1127 degree celcius.

POSTCERAMIC SOLDERS : flows below the pyroplastic range of the porcelain.

Recommended postsolder melting range : 710 - 743 degree celcius.

Ideal properties of Solder :

 Ease of flow at relatively low temperatures

 Sufficient freely flow when melted (phenomenon of wetting should be there).
 Strength compatible with that of the structure being soldered.
 Acceptable donor to give an inconspicious joint.
 Resistance to tarnish and corrosion.
 Resistance to pitting during heating and application.
 Low fusing than alloy.

SOLDERING FLUX :

 This substance is applied to a metal surface to remove oxides or prevent their

formation.
 Then the solder is free to wet and spread over the clean metal surface
 Fluxes are available in powder, liquid and paste forms.
 Common flux formula is Borax glass (55 parts), basic acid (35 parts) and silica (10
parts).
 Pastes are made by mixing powder with petrolatum. The petrolatum excludes oxygen
during heating and eventually carbonizes and then vaporizes.
 New fluxes are available for use with non-gold based alloys.
 All fluxes should kept away from contacting procelain otherwise, it may cause pitting
and procelain discoloration may take place.

SOLDERING ANTIFLUX

 Antiflux is used to limit spreading of solder. When the metal surfaces is clean, any
excess solder introduced into work gap will tend to flow into unwanted areas.
 Graphite is often used as an antiflux, but the carbon easily evaporate at higher
temperatures.
 A more reliable antiflux is iron oxide in chloroform.

SOLDERING INVESTMENT

HEAT SOURCE

a) Torch soldering : reducing portion of the flame is used to prevent oxidation.

The flame is directed at the connector immediately when the solder melts and is moved
around from position 1 to positions 2 and 3. This ensures that a complete meniscus is
formed.
b) Oven Soldering : a piece of solder is placed at the joint space, and the casting and
solder are heated simultaneously, performed under vaccum.

Oven soldering procedure. A, The invested partial fixed dental prosthesis (FDP)
before soldering. B, A small amount
of flux is added to the clean joint area. C and D, Solder is added, and the assembly
placed in the oven. E, The soldered FDP.
F, The soldering index is used to assess soldering accuracy. G, Oven-soldered
connector before finishing.

c) Microwave Soldering : advantage of using less energy, producing joints with

same strength as that with traditional methods.

d) Laser Welding : higher strength and reduced corrosion but susceptible to fatigue
failure.

SOLDERING TECHNIQUES : FOR METAL CERAMIC FIXED PARTIAL

DENTURES
a) Presoldering : with a high fusing solder i.e. 1100 degree celcius (pre-ceramic
solder)

A, Casting metal-ceramic alloys. B, Presoldering. C, Porcelain firing.

D, Casting type III and type IV gold alloys. E, Postceramic soldering. F,
Conventional soldering.
b) Postsoldering : with low fusing solder i.e . 750 degree celcius (post-ceramic
solder).

A, The prosthesis has been assembled with aplaster index.

B, After heating in a porcelain furnace, the solder is applied from the lingual.
Complete flow of the solder into the connector area.
C, Accuracy is verified by reseating the FDP into the index.
D, Completed restoration with highly polished connectors. E and F, The assembled
FDP.

SOLDERING TECHNIQUES

Armamenterium :

Autopolymerizing acrylic resin

• Zinc oxide–eugenol (ZOE) paste
• Impression plaster
• Mixing bowl
• Spatula
• Small brush
• Waxing instrument
• Sticky wax
• Baseplate wax
• Sprue wax
• Soldering investment
• Glass slab
• Soldering tripod
• Flux
• Solder
• Tongs
• Pickling solution

OCCLUSAL SOLDERING INDEX

Intraoral plaster or Zinc Oxide Eugenol is used to make an impression of the occlusal
surfaces of the fixed partial denture.

Soldering index (plaster) for posterior fixed dental prostheses.

A, A suitable carrier (e.g., baseplate wax) is trimmed to proper shape before a
registration is made with impression plaster (B). C, The plaster occlusal registration.
INVESTING

Investing procedure (occlusal index). A, The index is trimmed to ensure complete

seating of the castings.
B and C, The connector area is ground with a noncontaminating stone.
D, The restorations are steam cleaned.
E, The castings are seated firmly and luted into place with sticky wax.
F, Because glazed porcelain is damaged by contact with the investment, the porcelain
is protected with a layer of wax.
G, The wax flows into the connector areas and is
adapted below each connector to create an airway.
H, The soldering assembly is boxed.
I and J, When the assembly is filled with soldering investment, great care is taken to
ensure that there are no air bubbles in the investment.

AUTOPOLYMERIZING RESIN SOLDERING INDEX

1) A plaster or ZOE occlusal index is less suitable for the registration of anterior
restorations.
2) Because of the thinness of their incisal edges, these units are less stable, and
accurate repositioning is more difficult.
3) For this reason, autopolymerizing resin is recommended, although the resin burns
off during the procedure.
4) Therefore, the accuracy of the soldering procedure can be verified only
intraorally.

Soldering index (autopolymerizing resin).

A, Armamentarium.
B, A small brush dipped in resin monomer is touched to the polymer powder. This
forms a bead.
C, The restorations are thus connected, with resin extending onto the incisal edges of
all the retainers.
A, The castings are pressed firmly into a sheet of softened wax. Note
that the internal walls of the castings are exposed; the wax seals them.
B, Castings are filled with soldering investment and then inverted onto a patty of
investment.

Wax Removal and Preheating

Wax removal and preheating.

A and B, Boxing material is removed, and the wax residue is flushed out with boiling
water or an organic solvent.
C, The connector area must be free of contaminants.
D, A small amount of soldering flux is applied while the assembly is still warm.
E, The flux is carried into the connector area by capillary action. Then the assembly is
placed in the burnout furnace.

Torch Soldering (Low Heat)

A, The assembly positioned on a wire mesh over a Bunsen burner. B, A flexed piece
of solder is placed into the connector area. C, A sharply defined flame is preferable
for casting procedures.
D, A brush flame is more suitable for soldering. E, The assembly is heated evenly
until the solder melts. The solder must “spin” in the connector area to form a complete
connection (F).
 Torch Soldering (High Heat)

High-heat (before ceramic application) torch soldering with a gas-oxygen torch and a
miniature needle tip.

CONCLUSION

 Connectors join individual retainers and pontics. Rigid or nonrigid connectors can be
used.
 Connector size, shape, and position influence the success of a partial FDP.
 The use of soldered connectors can simplify the fabrication of larger FDPs, which
may be cast separately in groups of one or two units and assembled after their
individual fit has been verified.