PROSTHETIC

POLYMER AND
RESINS.
- MONICA SINGH
( JR1 )
 OUTLINE
Dentures and Denture Base Resins
Fabrication of Dentures
Acrylic Resins
Heat-Activated Denture Base Resins
Compression Molding Technique
Chemically Activated Denture Base Resins
Light-Activated Denture Base Resins
Physical Properties of Denture
Base Resins
Miscellaneous Resins and Techniques
Resin Teeth for Prosthetic Applications

 KEY TERMS
Inhibitor: Prevents unwanted polymerization of monomers,
extending shelf life and working time.
Liner: Replaces the tissue-contacting surface of a denture.
Long-term soft liner: Lasts up to a year, heat-processed for
durability.
Short-term soft liner (tissue conditioner): Lasts up to 14 days,
adapts to ridge changes, and contains plasticizers.
Rebasing: Replaces the entire denture base.
Relining: Replaces only the tissue-contacting surface of a
denture.
 Denture soft liner: Acts as a shock absorber and improves
denture retention.
THIS CHAPTER EXPLORES MATERIALS AND TECHNIQUES
FOR FABRICATING PROSTHETIC DENTURES AND FACIAL
PROSTHESES, FOCUSING ON POLYMERIC DENTURE BASE
RESINS, DENTURE TEETH, AND RESILIENT MATERIALS FOR
MAXILLOFACIAL PROSTHESES.
 DENTURES AND DENTURE
BASE RESIN
Complete denture: The Glossary of
Prosthodontic Terms (The Academy of
Prosthodontics, 2005) defines a
complete denture as a removable dental
prosthesis that replaces the entire
dentition and associated structures of
the maxilla or mandible. Such a
prosthesis is composed of artificial teeth
attached to a denture base. In turn, the
denture base derives its support
through contact with the oral tissues,
teeth, or dental implants
Focus: Denture base polymers,
processing systems, and polymerization
techniques.
 Enhancements: Methods to improve
fit and dimensional stability of resin
FABRICATION OF DENTURES.
Impression & Cast Fabrication :
Impression taken, gypsum cast
fabricated.
Record Base & Teeth Arrangement:
Resin record base made, teeth positioned
in wax, evaluated in the mouth.
Flasking & Dewaxing: Setup placed in
a brass denture flask, wax eliminated.
Resin Processing & Polymerization:
Mold cleaned, resin introduced,
polymerized.
 Final Recovery & Placement:
Denture retrieved, finished, and
 ACRYLIC RESINS FOR
DENTURE BASES.
Primary Material: Polymethyl methacrylate
(PMMA)
TYPES
Characteristics:
Based on the method used for its
Colorless, transparent solid (can be tinted). activation
Stable color, optical, and dimensional properties.  Heat activated resins
Adequate physical strength for dental  Chemically activated resins
applications.  Light activated resins
Processing Advantages:
Easy to fabricate.
Supplied as a powder-liquid system.
Powder: Prepolymerized PMMA beads.
Liquid: Non-polymerized methyl methacrylate.
Forms a workable mass when mixed.
 HEAT-ACTIVATED DENTURE
BASE RESINS.
Usage & Polymerization • Cross-Linking & Effects:
Used in nearly all denture bases • Enhances polymer strength by creating
interconnections
Polymerized using water bath or microwave•oven Prevents excessive solvent swelling
Composition (e.g., from alcohol exposure)
• Typically added at 1-2% concentration
Powder Component: • Storage Guidelines:
Prepolymerized PMMA spheres • Follow manufacturer’s temperature &
time recommendations
Benzoyl peroxide (initiator for polymerization) • Improper storage can alter resin
Liquid Component: properties and affect denture
performance
Methyl methacrylate monomer
Hydroquinone (inhibitor to prevent premature polymerization)
 Glycol dimethacrylate (cross-linking agent for strength &
deformation resistance)
 Hydroquinone is added as an inhibitor, which prevents
undesirable polymerization or “setting” of the liquid during
storage. Inhibitors also retard the curing process and thereby
 .
.POWDER
.

LIQUID
CHEMICAL BASIS FOR THE
FORMATION OF CROSS-
LINKED POLYMETHYL
METHACRYLATE
 Dentures are usually fabricated by one of the
following techniques
 1. Compression molding technique (usually heat
TECHNICAL
activated resins). CONSIDERAT
 2. Injection molding technique (heat activated IONS
resins). .

 3. Fluid resin technique (chemically activated

resins).
 4. Visible light curing technique (VLC resins).
 COMPRESSION MOLDING TECHNIQUE.
PREPARATION OF THE MOLD.
SELECTION AND APPLICATION
OF A SEPARATING MEDIUM.
POLYMER-TO-MONOMER RATIO.
POLYMER-MONOMER
INTERACTION.
DOUGH-FORMING TIME.
WORKING TIME.
PACKING.
INJECTION MOLDING
TECHNIQUE.
POLYMERIZATION PROCEDURE.
TEMPERATURE RISE.
INTERNAL POROSITY.
POLYMERIZATION CYCLE.
Steps in mold preparation (compression molding technique). A, POLYMERIZATION VIA
Completed tooth arrangement prepared for flasking process. B, MICROWAVE ENERGY.
Master cast embedded in properly contoured dental stone. C, Occlusal
and incisal surfaces of the
prosthetic teeth are exposed to facilitate subsequent denture
recovery. D, Fully flasked complete maxillary denture.E, Separation of
flask segments during wax elimination process. F, Placement of
 STEP-1. PREPARATION OF
THE MOLD.
Tooth Arrangement & Sealing- Prosthetic teeth are selected,
arranged for esthetics and function, and sealed to the master
cast.
Initial Flasking & Stone Application- Master cast is removed
from the articulator, coated with a separator, and placed in a
lower denture flask filled with dental stone.
Completion of Flasking- The upper flask section is positioned,
and another dental stone mix is poured to fully cover the teeth
and denture base, leaving minimal exposure for deflasking.
Final Hardening & Flask Sealing- The stone is allowed to set,
coated with separator, and additional stone is poured to
completely fill the flask before sealing.
Wax Elimination- The flask is immersed in boiling water for 4
minutes to soften and remove wax, leaving the prosthetic teeth
embedded in stone.
 Mold Cleaning- Residual wax is removed with solvent, followed
by a detergent wash and boiling water rinse to ensure a clean
STEP-2. SELECTION AND APPLICATION OF A
SEPARATING MEDIUM.
 Purpose – Prevents direct contact between denture
base resin and mold, avoiding polymerization issues
and material fusion.
 Composition:2% sodium alginate in water, glycerine,
 alcohol, sodium phosphate and preservatives
 Common Separator – Water-soluble alginate forms a
protective calcium alginate film on dental stone
surfaces.
 Application Process – Separator is applied with a
fine brush to a clean, warm stone mold.
 Precaution – Avoid contact with acrylic resin teeth to
ensure proper bonding with the denture base.
 Drying – Mold sections are positioned to prevent
pooling, and the separator is allowed to dry.
 STEP-3. POLYMER-TO-
MONOMER RATIO.
Importance of Ratio – Proper polymer-to-monomer ratio
ensures well-fitting denture bases with optimal physical
properties.
Polymerization Shrinkage – Chemical bonding of methyl
methacrylate molecules leads to a 21% volumetric
shrinkage, which can affect denture fit.
Prepolymerization Process – Manufacturers pre-shrink
resin by supplying polymer as a powder and monomer as a
liquid to minimize dimensional changes.
Standard Ratio – A 3:1 polymer-to-monomer ratio by
volume provides enough monomer for proper mixing while
limiting shrinkage to approximately 7%.
 Shrinkage Compensation – The initial setting expansion
of the gypsum mold and swelling of the polymerized
acrylic resin after exposure to water in the denture flask
and later, further compensate this shrinkage.
 STEP-4. POLYMER-MONOMER
INTERACTION.
Sandy Stage – Minimal molecular interaction;
polymer beads remain intact, creating a coarse,
grainy texture.
Stringy Stage – Monomer begins penetrating
polymer beads, partially dissolving polymer
chains, increasing viscosity, and making the
mixture sticky or stringy.
Doughlike Stage – More polymer dissolves in
monomer, forming a pliable, non-sticky dough
ideal for compression molding.
Rubbery/Elastic Stage – Monomer evaporates
and penetrates further into the polymer, making
the mass elastic and non-moldable.
 Stiff Stage – Continued monomer evaporation
leads to a dry, rigid mixture resistant to
STEP-5. DOUGH-FORMING
TIME.
 The dough-forming time is
the period required for a
resin mixture to reach a
doughlike stage. According to
ANSI/ADA Specification No.
12 (ISO 20795-1:2008) for
denture base resins, this
should occur within 40
minutes. Clinically, most
denture base products
achieve this consistency in
under 10 minutes.
 STEP-6. WORKING TIME.
Working time is the duration a denture base material
remains in the doughlike stage, crucial for
compression molding.
It requires a minimum working time of 5 minutes.
Temperature affects working time—refrigeration can
extend it but may cause moisture condensation.
Moisture contamination can degrade the resin’s
properties and should be prevented by storing it in an
airtight container.
 The container should remain closed until it reaches
room temperature to avoid condensation issues.
 STEP-7. PACKING
Resin Preparation & Placement:
Resin rolled into a rope, monomer applied, and
shaped into a horseshoe in the flask.
Initial Closure & Pressure Application:
Polyethylene sheet placed, flask pressed slowly to
ensure uniform resin flow.
Excess resin (flash) displaced.
Flash Removal & Final Closure:
Flash carefully removed, trial closures repeated
until none remains.
Flask closed without separator sheet.
Processing:
Flask transferred to a carrier to maintain pressure during
polymerization.
 Ensures proper fit, no voids, and accurate tooth
 STEP-8. INJECTION MOLDING
TECHNIQUE.
Injection Molding Process: Denture bases can be
fabricated using injection molding, where a flask is filled
with dental stone, the master cast is positioned, wax
elimination is performed, and resin is injected under
pressure before polymerization in a water bath.
Accuracy Debate: Injection molding may offer slightly
improved clinical accuracy compared to compression
molding, but its advantages are not entirely clear-cut.
Minimized Tooth Movement: One benefit of injection
molding is reduced tooth movement, which can enhance
overall denture fit.
Higher Curing Shrinkage: The lower viscosity resin
required for injection molding leads to a smaller polymer-to-
monomer ratio, increasing curing shrinkage and potentially
compromising palatal fit.
 Clinical Adjustment Needed: Due to shrinkage, a
deeper post-palatal seal preparation is necessary to
ensure proper contact between the denture base and
 STEP-9. POLYMERIZATION
PROCEDURE.
Initiation by Heat – Benzoyl peroxide in denture
base resins decomposes above 60°C, generating
free radicals that initiate chain-growth
polymerization.
Rapid Chain Growth – Free radicals react with
monomer molecules, leading to the rapid formation
of polymer chains.
Termination Methods – Polymerization ends
either by the combination of two growing chains or
by the transfer of a hydrogen ion between chains.
Role of Heat – Heat acts as an activator, triggering
benzoyl peroxide decomposition and the
polymerization process.
 Fabrication Process – The resin is heated in a
water bath at a controlled temperature, following
manufacturer guidelines for denture base
 STEP-10. TEMPERATURE
RISE.
Exothermic Reaction – The polymerization of
denture base resins releases heat, affecting the
final properties of the denture.
Temperature Lag – The resin heats up more slowly
initially because it is centrally located in the mold,
delaying heat penetration.
Rapid Temperature Increase – Once the resin
reaches around 70°C, benzoyl peroxide decomposes
faster, accelerating polymerization and heat
release.
Poor Heat Dissipation – Resin and dental stone are
poor thermal conductors, preventing the dissipation
of exothermic heat.
 Risk of Porosity – Excess heat can cause the
monomer to boil, leading to porosity in the final
 STEP-11. INTERNAL
POROSITY.
 Internal porosity occurs when the exothermic polymerization of resin
generates excessive heat, causing the monomer to boil and form voids
within the denture base.
 STEP-12. POLYMERIZATION
CYCLE.
Controlled Heating in
Polymerization: The
polymerization (curing) cycle must
be carefully regulated to prevent
uncontrolled temperature rise, which
can cause porosity due to monomer
boiling.
Temperature and Polymerization
Balance: Heating too fast (curve C)
can lead to porosity, while
insufficient heating (curve A) may
leave unreacted monomer. An
optimal cycle falls between these
Recommended Polymerization Techniques:
.
 Recommended curing cycles*
 1. Long cycle a. 74 °C for 8 hours
 b. 74 °C for 8 hours, then boil for 1 hour
 2. Short cycle - 74 °C for 2 hours, then boil for 1 hour of the thinner
portions (short cycle).
 Proper Cooling to Avoid Distortion: Fast cooling can result in
warpage of the denture due to differential thermal contraction of the
resin and gypsum mold The denture flask should cool gradually—
bench cool for 30 minutes, then immerse in cool water for 15 minutes
—to prevent dimensional changes.
 Storage Before Use: To maintain dimensional stability, the denture
should be stored in water until placement in the patient’s mouth.
STEP-13. POLYMERIZATION VIA
MICROWAVE ENERGY.
 Microwave Polymerization Feasibility: Polymethyl
methacrylate (PMMA) can be polymerized using
microwave energy due to the asymmetry of the methyl
methacrylate molecule.
 Specialized Materials Required: This method
requires a specially formulated resin and a non-metallic
flask.
 Use of Conventional Microwave Oven: A standard
microwave oven provides the necessary thermal energy
for polymerization.
 Advantages and Risks: The primary benefit is faster
polymerization, but overheating in thick sections can
cause porosity due to monomer boiling.
 Comparable Properties: Microwave-polymerized
denture bases have similar physical properties and fit to
those made using conventional compression molding
techniques.
CHEMICALLY
ACTIVATED
DENTURE
BASE RESINS.
• Technical
Considerations.
• Processing
Considerations.
• Fluid Resin
Technique.
CHEMICALLY ACTIVATED
DENTURE BASE RESINS.
 Chemical Activation Process: Chemically activated
denture base resins polymerize at room temperature without
thermal energy, using a tertiary amine (e.g., dimethyl-para-
toluidine) to decompose benzoyl peroxide and generate free
radicals.
 Comparison to Heat-Activated Resins: The key
difference is the initiation method—chemical vs. heat
activation—while all other polymerization factors remain the
same.
 Lower Polymerization Degree: Chemically activated
resins contain more unreacted monomer, which reduces
transverse strength (acting as a plasticizer) and may cause
tissue irritation.
 Dimensional Accuracy: These resins exhibit slightly less
shrinkage than heat-activated resins, leading to better
dimensional accuracy.
 Color Stability Issue: Tertiary amines in chemically
activated resins are prone to oxidation, causing
discoloration, though stabilizing agents can help minimize
this effect.
 STEP-1. TECHNICAL
CONSIDERATIONS.
Molding Technique: Chemically activated denture base
resins are typically molded using compression techniques,
similar to heat-activated resins.
Material Composition: The polymer (powder) and
monomer (liquid) are mixed to form a doughlike
consistency, following manufacturer guidelines.
Shorter Working Time: These resins polymerize faster
than heat-activated ones, requiring careful monitoring of
consistency and polymerization rate.
Prolonging the Initiation Period: Cooling the liquid
component or mixing vessel before mixing can slow
polymerization, extending the doughy stage and
increasing working time.
 Limited Trial Closures: Due to minimal working time,
usually only two trial closures are feasible, so precise
resin amounts and careful handling are essential.
.
 Liquid

Powder
 STEP-2. PROCESSING
CONSIDERATIONS.
Maintaining Pressure: After definitive flask closure,
pressure must be maintained throughout the
polymerization process to ensure proper denture formation.
Polymerization Time: Initial hardening occurs within 30
minutes, but the flask should remain under pressure for at
least 3 hours for sufficient polymerization.
Incomplete Polymerization: Chemically activated resins
never polymerize as completely as heat-activated resins.
Free Monomer Content: Chemically activated resins
contain 3%-5% free monomer, compared to 0.2%-0.5% in
heat-activated resins.
 Consequences of Incomplete Polymerization: Poor
polymerization can cause dimensional instability in the
denture base and may lead to tissue irritation.
 STEP-3. FLUID RESIN
TECHNIQUE.
Fluid Resin Technique Overview: This method uses a
pourable, chemically activated resin that is mixed, poured
into a mold, pressurized, and polymerized at room
temperature.
Molding Process: A tooth arrangement is sealed to a cast,
placed in a flask with reversible hydrocolloid, sprues and
vents are cut, wax is removed, and the resin is poured
through the sprue channels.
Polymerization and Finishing: The resin polymerizes in
30-45 minutes (longer is recommended), after which the
denture is deflasked, finished, polished, and stored in water
to prevent distortion.
Advantages: Improved tissue adaptation, reduced risk of
damage during deflasking, lower material costs, and
simplified processing.
 Disadvantages: Potential tooth shifting, air entrapment,
weak bonding to acrylic teeth, technique sensitivity, and
LIGHT-
ACTIVATED
DENTURE BASE
RESINS.
Composition and Activation: Visible light-activated
denture base resins consist of urethane
dimethacrylate, microfine silica, and acrylic resin
monomers, with camphorquinone as the
photosensitizer. Polymerization is initiated by high-
intensity visible light.
Material Form and Storage: These resins come in
sheet and rope forms, packed in lightproof pouches to
prevent premature polymerization.
Fabrication Process: Unlike conventional methods,
the denture base is molded directly on a cast, teeth are
positioned, and polymerization is done using a high-
intensity light source.
Three-Resin System: Modern light-activated systems
use three types of resins—base-forming (for the initial
denture base), tooth-setting (to attach teeth), and
contouring (for final shaping). Each layer is
polymerized with visible light.
 Finishing and Polishing: After polymerization, the
denture is removed from the cast and undergoes
finishing and polishing in a conventional manner.
PHYSICAL
PROPERTIES OF
DENTURE BASE
RESINS
Denture base resins must balance shrinkage, porosity, water
absorption, solubility, stress, and crazing for optimal fit and function.
 P.1- POLYMERIZATION
SHRINKAGE.
Polymerization Shrinkage: Denture base resins undergo
7% volumetric shrinkage and ≤1% linear shrinkage,
affecting fit.
Thermal Shrinkage: Heat-activated resins shrink due to
cooling, especially below the glass transition temperature
(105°C).
Chemically Activated Resins: These exhibit less
shrinkage (0.26%) than heat-activated resins (0.53%),
improving adaptation.
Dimensional Changes: Affected by investing medium,
resin introduction method, and activation temperature.
Vertical Dimension Changes: Fluid resin techniques
decrease vertical dimension, while heat- and chemically
activated resins increase it.
 Additional Factors: Gypsum expansion and water
sorption also impact final denture dimensions.
Linear shrinkage = αAT =(81 ppm/°C)(105 °C-20 °C)(100%)=
0.69%
 P.2- POROSITY
Heat Retention – Central areas trap heat, causing vaporization and porosity.
Improper Mixing – Uneven monomer distribution leads to shrinkage voids.
Low Pressure/Material Shortage – Irregular voids make the resin appear lighter.
Air Entrapment – Poor mixing and pouring trap air, forming large voids.
 Prevention: Use correct polymer-to-monomer ratios, mix thoroughly, wait for a dough-
like stage before packing, and ensure proper venting.
 P.3- WATER ABSORPTION
Absorption Mechanism – Polymethyl methacrylate
absorbs water via diffusion, causing polymer chains to
separate.
Effects on Polymer – Water absorption leads to slight
expansion and acts as a plasticizer, increasing polymer
chain mobility and stress relaxation.
Dimensional Changes – Water absorption offsets
polymerization shrinkage; chemically activated resins
expand slightly, while heat-activated resins contract
slightly.
Saturation Time – Denture bases take up to 17 days to
fully absorb water, with variations based on resin type
and storage conditions.
 Testing Standards – According to ANSI/ADA
Specification No. 12, acceptable water absorption is ≤
0.8 mg/cm² after 7 days of immersion.
 P.4- SOLUBILITY
Low Solubility – Denture resins are insoluble in oral
fluids but can dissolve in certain other liquids.
Testing Standard – ANSI/ADA Specification No. 12
measures solubility by weighing a test disk before and
after water immersion and drying.
Acceptable Weight Loss – Maximum allowable
solubility is 0.04 mg/cm², which is clinically
insignificant.
Historical Issue – Early (1940s) non-cross-linked
polymethyl methacrylate dentures swelled and
warped in ethanol.
 Modern Improvement – Cross-linking agents in
resin composition now prevent swelling and warping.
 P.5- PROCESSING
STRESSES
Internal Stresses from Shrinkage – During denture
base polymerization, monomer-to-polymer conversion
causes shrinkage, which can be inhibited by friction with
mold walls, leading to internal tensile stresses.
Thermal Shrinkage Stress – As the polymerized resin
cools below its glass transition temperature, it becomes
rigid and continues to shrink, generating additional
internal stresses.
Contraction Differential – Denture base resin and
dental stone contract at different rates, creating a
contraction differential that induces further stresses in the
material.
Processing Factors – Improper mixing, handling, or
poorly controlled heating and cooling during processing
can exacerbate stress buildup in the denture base.
 Distortion Risk – If these stresses are later relieved,
they can cause distortion in the denture base, affecting
 P.6- CRAZING
Crazing Definition & Impact – Stress relaxation can lead
to microcracks (crazing), which affect the esthetics and
physical properties of a denture but generally do not cause
major dimensional changes.
Clinical Appearance – Crazing appears as small linear
cracks, giving a “hazy” look in transparent resins and a
whitish appearance in tinted resins, making the denture
more prone to fractures.
Cause: Tensile Stress – Mechanical separation of polymer
chains due to tensile stress is a primary cause of crazing,
with cracks forming at right angles to the applied stress.
Cause: Solvent Action – Prolonged exposure to solvents
like ethyl alcohol can also cause crazing, with cracks
appearing in a more random pattern compared to stress-
induced crazing.
 Prevention & Advances – The development of cross-
linked denture base resins and improved acrylic resin
 P.7- STRENGTH
Factors Affecting Strength – Denture base resin strength
depends on composition, processing technique, and oral
environment conditions.
Testing & Deformation – A transverse test evaluates resin
strength, showing both elastic (recoverable) and plastic
(permanent) deformation under load.
Polymerization & Strength – Higher polymerization
increases resin strength, making the polymerization cycle
crucial for optimizing physical properties.
Processing Cycle Impact – Longer polymerization cycles
improve resin strength and deflection-load properties.
 Comparison of Activation Methods – Heat-activated resins
achieve higher polymerization, whereas chemically activated
resins have lower strength, increased residual monomer, and
reduced stiffness, though both have similar elastic moduli.
 P.8- CREEP
Viscoelastic Behavior – Denture resins act as
rubbery solids, displaying both elastic
(recoverable) and plastic (irrecoverable)
deformation under load.
Definition of Creep – When a sustained load is
applied, additional plastic deformation over time
is called creep.
Factors Affecting Creep Rate – Higher
temperature, applied load, residual monomer,
and plasticizers increase the creep rate.
 Comparison of Resins – At low stress, heat-
and chemically activated resins have similar
creep rates, but chemically activated resins
show a faster creep rate at higher stresses.
Impact Strength: Heat-activated denture resins
have a Charpy impact strength of 0.98–1.27 J, while
chemically activated resins are lower at 0.78 J. MISCELLANE
High-Impact Resins: High-impact resins like OUS
Lucitone 199 can have twice the impact strength of
conventional PMMA resins.
PROPERTIES
Modification for Strength: Increased impact
strength is achieved by adding rubbery, branched
comonomers like butyl acrylate.
Comparative Values: Impact strength values are
useful for product comparison but depend on factors
like specimen size, support distance, and notching.
 Hardness: Heat-activated resins can reach a
Knoop hardness of 20, whereas chemically
activated resins range from 16 to 18.
MISCELLANEOUS
RESINS AND
TECHNIQUES
 REPAIR RESINS.
 RELINING RESIN DENTURE BASES.
 REBASING RESIN DENTURES.
 SHORT- AND LONG-TERM SOFT DENTURE LINERS.
 RESIN IMPRESSION TRAYS AND TRAY MATERIALS.
 DENTURE CLEANSERS.
 INFECTION-CONTROL PROCEDURES.
 ALLERGIC REACTIONS.
 TOXICOLOGY.
 T.1- REPAIR RESINS
Denture Fracture & Repair: Despite their strength, denture
bases can fracture, but they can be repaired using light-, heat-,
or chemically activated resins.
Repair Preparation: The fractured denture is realigned and
luted with wax or modeling plastic, then a dental gypsum repair
cast is made. The fracture surfaces are trimmed, and a
separating medium is applied to prevent adhesion of the repair
resin.
Choice of Repair Resin: Chemically activated resins are
preferred despite lower transverse strength because they
polymerize at room temperature, avoiding heat-induced stress
and distortion.
Repair Process: Monomer is applied to old resin for bonding,
then increments of monomer and polymer are added. The repair
is slightly overfilled to compensate for shrinkage and
polymerized in a pressure chamber.
 Finishing & Standards: The repaired area is shaped,
 T.2- RELINING RESIN
DENTURE BASES.
Need for Relining & Rebasing: Dentures may require
modification due to ridge contour changes. Relining replaces only
the tissue surface, while rebasing replaces the entire base except
for the teeth.
Relining Process: A tissue impression is taken using the denture, a
gypsum cast is made, and resin is introduced using compression
molding. Chemically activated resins are preferred due to their
lower polymerization temperature, minimizing distortion.
Alternative Mounting Method: A specialized mounting assembly
can be used instead of flasking when chemically activated resins
are chosen, preserving proper denture alignment and simplifying
recovery.
Material Considerations & ANSI/ADA Standards: Some
intraoral relining resins generate excessive heat, potentially injuring
oral tissues. Materials must comply with ANSI/ADA Specification No.
17 for temperature limits, but some products meet repair standards
(ANSI/ADA No. 13) while failing temperature requirements.
 Caution with Home Use Products: Many over-the-counter
 T.3- REBASING RESIN
DENTURES.
Similar to Relining: Rebasing follows similar steps as
relining, starting with an accurate impression using the
existing denture as a custom tray.
Gypsum Cast & Mounting: A gypsum cast is created,
and the denture is mounted in a device to maintain
proper vertical and horizontal relationships.
Tooth Separation & Repositioning: The denture base
is removed, and the teeth are separated, then
repositioned in their original occlusal indices and waxed
onto a new baseplate.
Waxing & Resin Processing: The denture base is
shaped with wax, sealed to the cast, invested, and the
wax is removed before introducing resin into the mold
cavity.
 Finalization: After resin processing, the denture is
recovered, finished, polished, and consists of a new
base with the original teeth.
 T.4- SHORT- AND LONG-
TERM SOFT DENTURE
LINERS.
Impact on Denture Base Strength: Increasing the thickness of a soft liner reduces the
thickness of the denture base, weakening it. Additionally, adhesives and monomers used
with soft liners can partially dissolve denture bases, leading to fractures.
Cleaning Difficulties & Fungal Growth: Silicone soft liners are hard to clean, leading to
odor and taste issues. Although they do not directly support fungal growth, debris
accumulation in their porous structure promotes the growth of Candida albicans.
Limited Success of Cleaning Methods: Common cleaning methods, including
oxygenating and hypochlorite-based denture cleansers, can discolor and degrade soft
liners. Mechanical cleaning with a soft brush and mild detergent is necessary but may still
cause damage.
Shortcomings of Antimycotic Treatments: Antimycotic agents have been added to soft
liners to prevent fungal growth, but their effectiveness is short-lived, requiring further
research for long-term solutions.
Short-Term Nature of Existing Soft Liners: No currently available soft liner material is
completely satisfactory for long-term use due to issues like hardening, poor adhesion, and
fungal growth.
 Permanent Soft Liner Innovation (PNF-Based): A polyphosphazene fluoroelastomer
(PNF) liner, introduced in 1989, remains permanently soft, resists fungal growth, absorbs
chewing forces effectively, and does not rely on leachable plasticizers. It bonds well with
denture bases and provides long-term comfort. (Novus™ Resilient Liner )
 T.5- RESIN IMPRESSION
TRAYS AND TRAY MATERIALS
Custom Fit & Material Types – Resin impression trays, also called
custom trays, are made to fit individual patients using either light-
activated or chemically activated resin systems.
Material Advantages & Disadvantages – Light-activated resins
eliminate methyl methacrylate exposure but are costly and require special
light units. Chemically activated resins are cheaper but can cause contact
dermatitis.
Fabrication Process – A preliminary impression is taken with a stock
tray, followed by creating a gypsum cast. A spacer and separating medium
are applied before forming the tray.
Material-Specific Techniques – Light-activated resins come in sheet or
gel form, with sheets being preferred. Chemically activated resins are
mixed into a dough, rolled into a sheet, and adapted to the cast before
polymerization.
 Final Processing – After polymerization, trays are trimmed, rounded for
patient comfort, and evaluated intraorally for necessary refinements.
 T.6- DENTURE CLEANSERS.
Variety of Cleaning Agents – Patients use various agents to clean
dentures, including dentifrices, denture cleansers, detergents, bleaches, and
vinegar.
Common Commercial Cleansers – Most commercial products use
immersion techniques with powders or tablets containing alkaline
compounds and sodium perborate, which releases oxygen to loosen debris.
Bleach Usage & Risks – Diluted bleach can remove stains but may also
strip color from denture bases and relining materials. Bleach should never be
used on metal prostheses, as it causes darkening and irreversible damage.
Effects of Brushing & Abrasives – Toothbrushes alone or with mild
detergents and dentifrices cause minimal wear, while household abrasives
(e.g., kitchen cleansers) are harmful and can degrade denture surfaces.
 Patient Education – Patients should be properly educated on safe
cleaning methods to maintain the function and appearance of resin
prostheses.
 T.7- INFECTION-CONTROL
PROCEDURES
 Best Practices.
 Prevent microbial and viral cross-
contamination between patients and dental
personnel, including lab staff.
 New dental appliances must be disinfected
before leaving the lab.
 Existing prostheses should be disinfected
before and after lab procedures.
 Finishing and polishing materials must follow
infection-control guidelines.
 Autoclave rag wheels and use pumice per
unit-dose recommendations.
 T.8- ALLERGIC REACTIONS.
Potential Allergic Reactions – Allergic or toxic reactions to
polymethyl methacrylate are rare and may stem from
polymers, monomers, benzoyl peroxide, pigments, or
environmental interactions.
Irritation & Residual Monomer – True allergic reactions in
the oral cavity are uncommon; mild irritation may occur due to
residual monomer but is rare since properly processed
dentures contain less than 1% monomer.
Common Causes of Irritation – Most denture-related
soreness is due to poor hygiene, fungus overgrowth, 24-hour
denture wear, or ill-fitting bases rather than allergic reactions.
Contact Dermatitis Risk – Prolonged skin exposure to
monomers can cause contact dermatitis, particularly in dental
personnel handling fresh resins.
 Inhalation Hazards – Monomer vapors can be harmful, so
monomer use should be limited to well-ventilated areas.
 T.9- TOXICOLOGY
No Systemic Toxicity – Commonly used dental resins do
not produce systemic toxic effects in humans.
Minimal Residual Monomer Absorption – Processed
polymethyl methacrylate contains very little residual
monomer, which is largely blocked by oral mucosa and
tissues from entering the bloodstream.
Rapid Monomer Breakdown – Any monomer that reaches
the bloodstream is quickly hydrolyzed into methacrylic acid
and excreted, with a half-life of 20 to 40 minutes.
Metal Oxide Pigment Use – Historically, toxic metal oxide
pigments (cadmium/selenium) were used in denture resins
but were locked within the polymer network and used in low
concentrations.
 Safer Pigments Adopted – Most manufacturers have
replaced metal oxide pigments with safer organic pigments
like Cromophtal Red BRN.
RESIN TEETH FOR
PROSTHETIC
APPLICATIONS
Composition & Cross-Linking – Most artificial teeth are made
of polymethyl methacrylate (PMMA) resins, with high cross-linking
at occlusal and incisal surfaces for enhanced wear resistance and
reduced cross-linking at cervical areas for better bonding with
denture bases.
Bonding & Surface Preparation – Proper bonding between
resin teeth and heat-activated denture base materials requires
removing wax and contaminants, flushing gypsum molds, and
wetting ridge-lap surfaces with monomer before resin
introduction.
Hybrid Teeth & Bonding Challenges – Hybrid teeth combine
composite resin and PMMA for improved wear resistance but have
weaker chemical bonding with denture bases. Manufacturers add
PMMA to ridge-lap and lingual surfaces to enhance bonding.
Chemical vs. Mechanical Retention – Heat-activated resins
bond chemically with resin teeth, while chemically activated
resins primarily use mechanical retention. Chemical bonding in
the latter requires softening the resin with a methylene chloride-
monomer mix.
 Resin vs. Porcelain Teeth – Resin teeth are impact-resistant,
easier to adjust, and chemically bond with denture bases, while
porcelain teeth have better dimensional stability and wear
MATERIALS FOR
MAXILLOFACIAL
PROSTHETICS
WHY?
Maxillofacial prostheses have been used for
centuries, with early examples from ancient Egypt
and China. In the 16th century, Ambroise Paré
documented prosthetic techniques, and
advancements continued, especially after World
Wars I and II, when the need for reconstruction
grew.
 Despite progress, no material fully meets the
ideal requirements—being biocompatible, strong,
stable, affordable, and skin-like in color and
texture. Current materials also face challenges
with durability and resistance to environmental
factors, emphasizing the need for further
innovation in maxillofacial prosthetics.
 M.1- LATEXES
Properties & Limitations of Natural Latex – Latex is soft,
inexpensive, and lifelike but weak, degrades quickly,
and has poor color stability, making it unsuitable for
long-term maxillofacial prostheses.
Synthetic Latex Advantages – A terpolymer of butyl
acrylate, methyl methacrylate, and methyl
methacrylamide offers better transparency, enhanced
translucency, and improved blending through sprayed
colorants.
 Limited Applications – Despite its benefits, synthetic
latex requires complex processing and has a short
lifespan of only a few months, restricting its use in
maxillofacial prosthetics.
 M.2-VINYL PLASTISOLS.
Composition & Use – Vinyl plastisols are
thick liquids made of vinyl particles in a
plasticizer, used in maxillofacial applications
with added colorants for skin tone matching.
Processing – These materials require
heating to achieve the desired physical
properties.
 Limitations – Over time, plastisols harden
due to plasticizer migration and degrade
under ultraviolet light, limiting their long-
term usefulness.
 M.3- SILICONE RUBBERS
Introduction & Types – Silicones have been used in maxillofacial
prosthetics since the 1950s and are available as room-temperature-
curing and heat-curing variants, each with unique properties.
Room-Temperature-Curing Silicones – These cure by acetic acid
evaporation and are characterized using dyed fibers and pigments.
They are molded in gypsum, epoxy, or metal molds but have lower
strength and color stability.
Heat-Curing Silicones – These require milling, pressure molding,
and heat polymerization at 180°C. They offer superior strength and
color stability, with pigments mixed intrinsically for better
aesthetics.
Common Issues – All silicones are prone to fungal growth and
fraying at edges, leading to the development of polyurethane
bonding, though polyurethane may discolor over time.
 Heat-Curing Challenges – Heat-curing silicones require
specialized equipment like milling machines, presses, and metal
molds, making the fabrication process complex and time-
consuming.
 M.4- POLYURETHANE
POLYMERS
 Polyurethane is used in maxillofacial
prosthetics, requiring precise mixing of
three components and room-temperature
polymerization in stone or metal molds.
While it offers a natural feel and
appearance, it deteriorates quickly and is
prone to fungal growth, limiting its
durability.
 M.5- CHLORINATED
POLYETHYLENE
Development & Purpose – Chlorinated polyethylene (CPE) was
explored in the 1970s and 1980s to address the limitations of
latex, vinyl plastisol, silicone, and polyurethane in maxillofacial
prosthetics.
Key Advantages – CPE offers improved edge strength, permanent
elasticity, and resistance to fungal growth, making it a durable
alternative.
Patient Preference – A clinical trial found that first-time
prosthetic users accepted CPE, but those previously using silicone
prostheses preferred silicone.
Aesthetic Enhancements – Techniques for layering CPE in molds
were developed to enhance color depth and natural appearance.
 Further Research – Reviews by experts, such as Lemon et al.
(2005), provide insights into facial prosthetic rehabilitation and
advancements in biomaterials.
 THANK YOU.
LET’S KEEP
TRANSFORMING
SMILES!