The document summarizes the steps taken to fabricate a new denture using the existing denture as a custom tray and bite registration. Key steps included: 1) taking an impression and pouring a master cast; 2) setting up the teeth and denture base on an articulator; 3) flasking, packing, and curing the acrylic; 4) deflasking, finishing, and polishing the new denture. The existing denture helped establish vertical dimension and bite registration to fabricate a replacement denture.

1. by EUGENE ROYZENGURT

2. FINAL IMPRESSION
 IN THIS CASE A PREVIOUS DENTURE WAS USED
AS A CUSTOM TRAY AND A BITE RIM.

3. BOXING UP A FINAL IMPRESSION
 WE USED WONDERFILL PUTTY AND FLASK.

4. MASTER CAST
 VACUUM MIX THE STONE FOR A BETTER MASTER
CAST AND FIT.

5. ARTICULATE THE CASTS
 USE THE ORIGINAL DENTURE AND BITE
REGISTRATION TO FACILITATE THE MOUNT.

6. MYOSTATIC OUTLINE
 REMOVE THE ORIGINAL DENTURE FROM THE
CAST AND DRAW A MYOSTATIC OUTLINE.

7. FABRICATE A BITE RIM
 SINCE THE VERTICAL WAS ESTABLISHED WITH THE ORIGINAL, NO WAX
BITE WAS NECESSARY. THE RIM WAS MADE TO THE OUTLINE USING A
VLC MATERIAL.

8. SELECT TEETH
 WE SELECTED THE MOULD AND SHADE TO MATCH THE PREVIOUS
APPLIANCE AND THE OPPOSING FULL UPPER DENTURE.

9. DENTURE SETUP
 THE CASE WAS SET UP AND BALANCED. CURVE OF SPEE AND WILSON
WERE UTILIZED. EXCURSIVE AND PROTUSIVE FUNCTION UTILIZED.

10. FLASKING DENTURE
APPLIANCE IS REMOVED FROM THE ARTICULATOR. LUBRICANT IS
APPLIED TO CAST AND FLASK. FIRST POUR IS DONE IN PLASTER.

11. SEPARATING FIRST POUR
 APPLY TWO COATS OF SEPARATOR ON PLASTER AND MASTER CAST. DO
NOT APPLY SEPARATOR TO THE DENTURE. ALLOW THE SEPARATOR TO
DRY BETWEEN COATS.

12. SECOND POUR
 INSERT THE SECOND PART OF THE FLASK AND MIX FLOW STONE TO
CREATE THE SECOND POUR. POUR SLOWLY TO MINIMIZE THE
BUBBLES.
 FLOW STONE FROM WHIPMIX DOES NOT REQUIRE ANY TYPE OF
VIBRATION AND IN GENERAL WILL CREATE A NICE SMOOTH FINISH.
 IT IS IMPORTANT TO HAVE THE EDGES OF THE FLASK CLEANED,
OTHERVISE THE STONE WILL LEAK OUT OF THE SIDES OF THE FLASK.
 POUR ONLY ENOUGH STONE TO BARELY COVER THE INCISAL AND
OCCLUSAL SURFACES OF THE TEETH.

13. SECOND POUR

14. SECOND POUR CLEAN UP
 USE A DRY OR A GLOVED FINGER TO REMOVE
THE STONE FROM THE INCISAL AND OCCLUSAL
SURFACES OF THE TEETH. THIS STEP WILL HELP
WITH DEFLASKING LATER ON.
 WAIT UNTIL THE STONE IS SLIGHTLY SET UP
BEFORE DOING SO.
 THE SURFACE OF THE STONE WILL BECOME
SLIGHTLY HAZY WHEN STONE IS STARTING TO
SET UP.

15. SECOND POUR CLEAN UP

16. APPLY SEPARATOR
 APPLY TWO COATS OF SEPARATOR TO SECOND
POUR. ALLOW TO DRY BETWEEN COATS.

17. THIRD POUR
 MIX UP LAB STONE AND VIBRATE IN THIRD
POUR.

18. PLACE FLASK COVER
 PLACE FLASK COVER ON TOP OF THIRD POUR SLOWLY WHILE THE
STONE IS STILL WET. GETLY HAMMER IN THE TOP COVER.

19. FLASK CLEAN UP
 REMOVE THE FLASH OF STONE FROM THE FLASK
AND ALLOW THE STONE TO SET COMPLETELY.

20. BOIL OUT
 PLACE FLASK IN BOILING WATER FOR FIVE MINUTES.

21. BENCH
 REMOVE THE FLASK FROM WATER AND ALLOW THE WAX TO SOFTEN
FOR ADDITIONAL THREE MINUTES BEFORE OPENING THE FLASK.

22. OPEN THE FLASK
AFTER OPENING THE FLASK CLEAN UP THE EDGES OF
THE FLASK AND REMOVE THE BASE PLATE.

23. WASH OUT
 WASH OUT THE WAX WITH BOILING WATER.

24. DETERGENT
 APPLY DETERGENT WITH A BRUSH TO REMOVE ANY RESIDUAL
WAX AND OIL. RINSE WITH BOILING WATER.

25. RINSE
 RINSE THE FLASK AND MODELS WITH CLEAN
BOILING WATER FROM A SEPARATE SOURCE.

26. SEPARATOR
 AS SOON AS THE FLASK IS DRY, APPLY TWO
COATS OF SEPARATOR ON THE MODELS. ALLOW
TO DRY THOROUGHLY BETWEEN COATS. USE
GREAT CARE TO AVOID APPLYING THE
SEPARATOR TO ANY OF THE TOOTH SURFACES.
 USE SMALL BRUSH TO APPLY SEPARATOR
AROUND THE TEETH.

27. SEPARATOR

28. COOL THE FLASK
 ALLOW FLASK TO COOL TO ROOM
TEMPERATURE.
 MAKE SURE NOT TO SKIP THIS STEP.
 IF THE FLASK IS PACKED HOT, IT WILL CAUSE
POROSITY IN ACRYLIC.

29. BONDING AGENT
 APPLY BONDING AGENT TO EXPOSED SURFACES OF
THE TEETH. THIS WILL ENSURE PROPER ADHESION
BETWEEN BASE ACRYLIC AND TOOTH SURFACE.

30. MIXING ACRYLIC
 PLEASE FOLLOW MANUFACTURER’S
SPECIFICATIONS WHEN MIXING ACRYLIC.
 ALWAYS ADD POWDER TO LIQUID TO AVOID
BUBBLES.

31. PACKING ACRYLIC
 PLACE A SMALL AMOUNT OF ACRYLIC DOUGH
DIRECTLY ON THE TEETH. PLACE A SEPARATING
SHEET ON TOP OF THE ACRYLIC. CLOSE THE
FLASK AND PLACE IN THE PNEUMATIC PRESS FOR
TRIAL PACKING.
 REMOVE FLASK FROM THE PRESS. OPEN THE
FLASK AND REMOVE THE SEPARATING SHEET.
 ADD ANOTHER SMALL AMOUNT OF ACRYLIC
OVER THE INITIAL ACRYLIC.

32. PACKING ACRYLIC

33. ADDING ACRYLIC
 PLACE ADDITIONAL ACRYLIC. PUT A
SEPARATING SHEET AND INSERT IN THE
PNEUMATIC PRESS.
 KEEP ADDING ACRYLIC INCREMENTALLY UNTIL
THE ENTIRE MOULD IS FILLED.
 MAKE SURE YOUR HANDS ARE CLEAN FROM ANY
FOREIGN DEBRIS, OTHERWISE YOU WILL HAVE
CONTAMINATED DENTURE BASE.

34. ADDING ACRYLIC

35. TRIM EXCESS
 TRIM ANY EXCESS ACRYLIC WITH A SHARP INSTRUMENT.

36. FINAL CLOSING
 CLOSE THE FLASK WITHOUT ANY SEPARATING SHEETS, AND
PLACE IN THE PNEUMATIC PRESS ON A FINAL CLOSE SETTING.

37. BENCH CURE
 PLACE FLASK IN THE PROCESSING PRESS AND
CLOSE TIGHTLY.
 ALLOW CASE TO BENCH CURE FOR TWENTY
MINUTES.
 BENCH CURING WILL INCREASE ADHESION
BETWEEN THE TEETH AND THE BASE ACRYLIC,
AS WELL AS REDUCE POROSITY IN THICKER
DENTURE BASES.

38. BENCH CURE

39. CURING
 PLACE FLASK COMPRESS IN A WATER BATH AND
FOLLOW THE MANUFACTURER’S INSTRUCTION
FOR CURING.

40. BENCH COOLING
 AFTER THE ACRYLIC HAS BEEN CURED, ALLOW THE FLASK TO
BENCH COOL FOR AT LEAST FIFTEEN MINUTES.

41. WATER COOLING
 REMOVE THE PROCESSING PRESS AND PLACE FLASK
IN A COLD WATER BATH FOR FIFTEEN MINUTES.

42. DEFLASKING
 DEFLASK, USING TRADITIONAL METHODS.
 WE UTILIZED A PNEUMATIC CHISEL IN THIS CASE.

43. REMOUNT AND EQUILIBRATE
 REMOUNT CAST ON THE ARTICULATOR AND
EQUILIBRATE THE APPLIANCE.

44. WALLNUT SHELL
 REMOVE APPLIANCE FROM THE CAST AND USE THE WALLNUT
SHELL BLASTER TO REMOVE ANY RESIDUAL STONE.

45. BULK TRIM
 REMOVE THE BULK OF EXCESS WITH A LATHE.

46. CONTOUR AND PREPOLISH
 USE HANDPIECE AND SMALL BURS AND WHEELS TO
CONTOUR AND PREPOLISH.

47. PUMICE
 USE MEDIUM GRIT PUMICE TO REMOVE
SCRATCHES AND CREATE A LOW SHINE.

48. HIGH SHINE
 USE A HIGH SHINE COMPOUND ON EITHER A LATHE
OR A HANDPIECE TO CREATE A LUSTER FINISH.

49. DISINFECT
 PLACE THE FINISHED APPLIANCE IN A PLASTIC
BAG. ADD DISINFECTANT THAT IS SAFE FOR
ACRYLIC AND SEAL THE BAG.

50. THE END