Accuracy in the Plaster Model of Total Prosthetic Plates in Three Different Manufacturing Methods: In Vitro Study
Abstract
:1. Introduction
2. Materials and Methods
2.1. Creation of the Model
- First impression: The impression of the upper arch is taken using alginate (irreversible hydrocolloid) and a commercial impression tray.
- First plaster model: From the alginate impression, a hard plaster model is obtained (the plaster we use is HydrocalKerrTM) on which to build the individual resin impression tray (impression tray resin LC—Henry Schein®).
- Second impression: The second impression is taken using Permlastic™ condensation polysulfide and the individual impression tray built on the previously obtained plaster model.
- Second plaster model: From the second impression, the definitive model is obtained using Class IV extra-hard plaster in order to have high resistance characteristics and smooth surfaces (Suprastone ultra-hard chalkTM) (Figure 1).
2.2. Construction of the Plates with the Three Methods
2.2.1. Traditional Method
- Waxing of the model: The plate is created on the plaster model with a sheet of wax (the teeth have been mounted in our model).
- Putting into the muffle: The plaster model with the waxing is inserted into the muffle (mold and counter-mold), and everything is placed in a kettle to melt the wax. Once the muffle has been opened and the mold and counter-mold have been washed with hot water to eliminate wax residues, we proceed to carry out the retentions in the teeth.
- Resin packing: The resin we have chosen is Promolux, a hot polymerizing resin with color stability based on methyl methacrylate. Once the powder is mixed with the liquid and the initial plasticity consistency is obtained, it is inserted into the muffle.
- Polymerization: The closed muffle is inserted into the kettle at a programmed temperature of 70 degrees for 30–60 min, and then the kettle brings the temperature to 100 degrees for 30 min.
- Finishing: After polymerization, the flask is opened, the resin prosthesis is removed, and it is finished with suitable cutters and rubbers (Figure 2).
2.2.2. CAD/CAM Method for Milling
- Model scanning: The plaster model inserted into the scanner is scanned to obtain a three-dimensional digital model using software.
- Design: The digital model obtained from the scan is imported into CAD software (Exocad®), where the digital model of the prosthetic plate is created
- Milling: Once the design of the prosthesis in the CAD software is completed, a CAM file is generated which is sent to a software that manages the milling machine (HyperDent®) that contains the information necessary for milling. A micro-filled disk in PMMA (Smile Cam®) is milled until the previously designed plate is obtained
- Verification and adaptation: The prosthetic plate is then tried on the model to verify the adaptation (Figure 3).
2.2.3. CAD/CAM Method for Addition
- Model scanning: The plaster model inserted into the scanner is scanned to obtain a three-dimensional digital model using software.
- Design: The digital model obtained from the scan is imported into Exocad® CAD software, where the digital model of the prosthetic plate is created.
- Printing of the plate: The digital model is prepared for printing, correctly positioning the prosthesis on the virtual support plate. The CAD file is sent to the Phrozen® 3D printer, where the printing parameters are set via a software that manages the 3D printer (Chitubox®), and the plaque is formed layer-by-layer. A Raydent® composite resin was used.
- Finishing: After printing, the plate is removed from the support plate and subjected to finishing and testing on the model to check the fit (Figure 4).
2.3. Creation of the Silicone Models to Be Examined
- a—Creation of the silicone with the prosthetic plate n° 1:Figure 6. (a) Base paste and catalyst mixture; (b) Fit Checker applied to the plate; (c) plate inserted into the model and application of controlled pressure; (d) silicone obtained from plate n°1.Figure 6. (a) Base paste and catalyst mixture; (b) Fit Checker applied to the plate; (c) plate inserted into the model and application of controlled pressure; (d) silicone obtained from plate n°1.
- b—Creation of the silicone with the prosthetic plate n. 2:Figure 7. (a) Base paste and catalyst paste; (b) mixture applied in the base obtained by milling; (c) Fit Checker applied to the plate; (d) silicone obtained from plate n° 2.Figure 7. (a) Base paste and catalyst paste; (b) mixture applied in the base obtained by milling; (c) Fit Checker applied to the plate; (d) silicone obtained from plate n° 2.
- c—Creation of the silicone with the prosthetic plate n° 3:Figure 8. (a) Base paste and catalyst paste; (b) mixture applied in the base obtained by milling; (c) load applied on the model; (d) silicone obtained from plate n° 3.Figure 8. (a) Base paste and catalyst paste; (b) mixture applied in the base obtained by milling; (c) load applied on the model; (d) silicone obtained from plate n° 3.
2.4. Statistics of the Data Collected
3. Results
4. Discussion
5. Conclusions
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Conflicts of Interest
References
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Parameters that can Influence the Construction Method |
operator experience |
alteration of polymerization times |
type of resin used |
Parameters that can influence the CAD design method |
software used |
operator experience for design |
thickness and contour of the plaque |
properties of the material used |
accuracy of scanning and virtual model |
resolution of the virtual model |
Parameters that can influence CAM milling |
feed rate and tool rotation speed |
type of cutter or tip to determine accuracy and surface finish |
milling machine parameters and machine accuracy |
milling machine calibration and cooling system |
type of material to be milled and shape and size of the plate |
Parameters that can influence the CAD design method |
software used |
operator experience for design |
thickness and contour of the plaque |
properties of the material used |
accuracy of scanning and virtual model |
resolution of the virtual model |
Parameters that can influence CAM by addition |
type of printer |
feed rate and set speed |
Printer parameters |
calibration and cooling system |
type of material and shape and size of the plate |
Silicone 1 | Silicone 2 | Silicone 3 | ||||||
---|---|---|---|---|---|---|---|---|
Sample | Sex | Age | Area A | Area B | Area A | Area B | Area A | Area B |
Dentist 1 | M | 38 | 1 | 2 | 3 | 1 | 2 | 2 |
Dentist 2 | M | 46 | 1 | 1 | 2 | 2 | 3 | 2 |
Dentist 3 | M | 42 | 1 | 1 | 2 | 3 | 1 | 2 |
Dentist 4 | M | 39 | 1 | 1 | 3 | 2 | 2 | 3 |
Dentist 5 | F | 50 | 1 | 1 | 2 | 2 | 3 | 2 |
Dentist 6 | F | 41 | 2 | 2 | 1 | 1 | 3 | 3 |
Dentist 7 | M | 38 | 1 | 1 | 2 | 3 | 2 | 2 |
Dentist 8 | F | 46 | 1 | 1 | 2 | 3 | 1 | 1 |
Dentist 9 | M | 46 | 1 | 2 | 3 | 1 | 2 | 3 |
Dentist 10 | M | 44 | 2 | 1 | 1 | 3 | 2 | 2 |
Dentist 11 | M | 60 | 2 | 1 | 1 | 1 | 3 | 3 |
Dentist 12 | F | 41 | 1 | 2 | 3 | 1 | 2 | 2 |
Dentist 13 | M | 42 | 1 | 2 | 2 | 1 | 3 | 3 |
Dentist 14 | M | 44 | 1 | 1 | 2 | 3 | 2 | 3 |
Dentist 15 | M | 53 | 1 | 2 | 2 | 1 | 2 | 3 |
Total | 18 | 21 | 31 | 28 | 33 | 36 |
Silicone | Average Area A | Average Area B | Variance A | Variance B | Deviance A | Deviance B |
---|---|---|---|---|---|---|
Silicone 1 | 1.2 | 1.4 | 0.16 | 0.28 | 0.4 | 0.52 |
Silicone 2 | 2.06 | 1.86 | 0.31 | 0.78 | 0.55 | 0.88 |
Silicone 3 | 2.2 | 2.4 | 0.42 | 0.37 | 0.64 | 0.60 |
µtotale | 1.8533 |
---|---|
SST | 1.095 |
SSB | 1.095 |
SSW | 32.48 |
dfb | 5 |
dfw | 84 |
MSB | 0.219 |
MSW | 0.386 |
F-value | 0.568 |
p-value | 0.735 |
Campione/Area | 1 | 2 | 3 |
---|---|---|---|
SILICONE 1/Area A | 12 | 3 | 0 |
SILICONE 1/Area B | 9 | 6 | 0 |
SILICONE 2/Area A | 3 | 8 | 4 |
SILICONE 2/Area B | 7 | 3 | 5 |
SILICONE 3/Area A | 2 | 8 | 5 |
SILICONE 3/Area B | 1 | 7 | 7 |
Research Gap |
---|
Reduced number of prosthetic plates |
Small sample of dentists involved in the evaluation |
The adaptability assessment was carried out by visual examination which is a subjective examination |
Future Research Ideas |
Experimental studies with the aim of establishing objective parameters with larger samples of plates and observers to allow for the identification of the most subtle differences between the different construction methods with precise and comparable data |
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Ceraulo, S.; Barbarisi, A.; Selvaggio, L.; Caccianiga, G.; Lauritano, D. Accuracy in the Plaster Model of Total Prosthetic Plates in Three Different Manufacturing Methods: In Vitro Study. Prosthesis 2025, 7, 42. https://doi.org/10.3390/prosthesis7020042
Ceraulo S, Barbarisi A, Selvaggio L, Caccianiga G, Lauritano D. Accuracy in the Plaster Model of Total Prosthetic Plates in Three Different Manufacturing Methods: In Vitro Study. Prosthesis. 2025; 7(2):42. https://doi.org/10.3390/prosthesis7020042
Chicago/Turabian StyleCeraulo, Saverio, Antonio Barbarisi, Leonardo Selvaggio, Gianluigi Caccianiga, and Dorina Lauritano. 2025. "Accuracy in the Plaster Model of Total Prosthetic Plates in Three Different Manufacturing Methods: In Vitro Study" Prosthesis 7, no. 2: 42. https://doi.org/10.3390/prosthesis7020042
APA StyleCeraulo, S., Barbarisi, A., Selvaggio, L., Caccianiga, G., & Lauritano, D. (2025). Accuracy in the Plaster Model of Total Prosthetic Plates in Three Different Manufacturing Methods: In Vitro Study. Prosthesis, 7(2), 42. https://doi.org/10.3390/prosthesis7020042