OPEN ACCESS Freely Available Online

Clinical Innovation

Innovative Method for Fabrication of Microwavable Denture Flasks

Sunil Dhaded a , Rajesh Prajapat
a

, Neha Dhaded

Abstract
a

Department of Prosthdontics, A.M.ES

Dental College and Hospital, Raichur, India.

b

K.L.ES

V.K.

Institute

of

Dental

Sciences and research centre, KLE University, Belgaum, India.

Introduction: Microwavable denture flasks for polymerization of acrylic resin are commercially available. However they are expensive and smaller in size, large maxillofacial prosthesis cannot be fabricated in them. The objective of this report is to showcase a simple technique for the fabrication of microwavable denture flasks which is economical and larger in size. Clinical innovation: A method of making dental stone flask pattern and a latex rubber mold was used to produce microwavable denture flasks. These flasks are made from the fiberglass liquid resin that is strengthened by the addition of chopped fiberglass strands. Discussion: Microwavable denture flasks can be made that will be simple, economical and large enough to accommodate the maxillofacial prosthesis. These flasks are strong enough for compression molding and allow successful microwave polymerization of acrylic resin denture bases.

Correspondence to: Sunil Dhaded Department of Prosthdontics, A.M.ES Dental College and Hospital, Raichur, India. Tel: +98-44101555 sunildhaded2000@yahoo.com

Received: March 10, 2011 Accepted: September 1, 2011 Published: September 5, 2011

Key words: Fiberglass liquid resin; Fiberglass strands; Microwavable denture flask; Liquid latex rubber.

Copyright: 2011 Dhaded S, et al. This is an open-access article distributed under the terms of the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original author and source are credited.

doi:10.5436/j.dehy.2011.2.00043

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Introduction
Due to the rapid development in dental material sciences, acrylic resin can also be polymerized by microwave irradiation, as first reported by Nishii [1] in 1968. There are substantial advantages of using microwave energy for curing of acrylic resin rather than the conventional water bath method. These advantages are greatly reduced curing time, less cumbersome equipment, a cleaner method of processing and better adaptation to the cast [2]. The conventional metal (brass) flask cannot be used for microwave processing as microwave radiation cannot pass through the metal, instead, a fiberreinforced plastic denture flask system (US Shizai Corp, Santa Monica, Calif) was developed and became commercially available in 1985 [3]. Unfortunately, the most disadvantages of microwave technique were related to fiber reinforced flasks as these flasks are relatively expensive, small and have a tendency to break down after processing several dentures [4]. Procedure for making oversized microwavable denture flask using metal template was also described Mc Kinstry [3]. Nevertheless, this article describes a simple method for making microwavable denture flasks that are capable of holding large maxillofacial prosthesis, using

commonly available denture flasks hence eliminating the use of metal template and also making the procedure economical.

Clinical innovation
The following materials are used to make a microwavable denture flask: Middle section of conventional Brass flask (Jabbar & Co. India). Bowl and spatula. Dental stone (Kalstone, Kalabhai Dental P Limited, India). Petroleum jelly (Medisoft Pvt. Ltd. India). Clean tile. Lead pencil. Three 60 ml plastic syringes (Dispo Van, Hindustan Syringe & Medical Device Ltd] Three 3/8 inch Metal bolts that are 4 inches long as well as six washers and three nut to fit. Liquid latex rubber (DCMM solution, Devi and CO. Banaglore, India). A Paint brush 11/2 inches wide. Chopped Fiberglass Fibers (Naptha Resins, Peneya, Banaglore, India).

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Fiberglass liquid resin and catalyst (Naptha Resins, Peneya, Bangalore, India). Fiberglass liquid resin is commercially available for use in auto body repair shops. Power drill (Available at Carpenter or Hardware Shops). Three pieces of window or plate glass approximately 8 inches square.

borders touched the outline on the tile. Soak all parts of stone flask in saturated solution of calcium sulphate to prevent expansion of stone [5].

Procedure to create bolt guide

Take a 60 ml syringe (without the piston) cut the nozzle end of the syringe so that both the ends are open. Standardize the position and dimension for the screw hole, by placing the syringe along the sides of the flask model. Cut the syringe into 3 parts according to the height of the three part of the flask model. Apply petroleum jelly on the inner surface, align the three parts of syringe, make a thick mix of stone and pour into the syringe. Similarly make two more sets of bolt guides for the other two sections. After the stone has hardened separate the plastic syringe. Trim on one side to create a flat surface so as to attach it to the flask model. Align all the stone guides in their respective places. Leave 4 mm of space between two bolt guides. Make a mixture of stone and place in between the bolt guide and flask model. Shape the stone to make a smooth transition between the guide and the flask model. After stone sets separate all the parts of the stone flasks and with a sharp knife complete the shaping to form a smooth surface (Appendix 2).

Procedure for making dental stone flask

Dental stone flasks were made using mid section of conventional brass flask. Apply petroleum jelly to the midsection, make a thick mix of dental stone and apply on the outer surface (Appendix 1). After it sets, remove the brass flask by gently tapping and trim the excess material. Follow the same procedure as mentioned above to make the lower section. Then place it on unset stone base made using thick mix of dental stone and seal it from border. Scoop out stone of approximately two inch diameter from base, after final set of the stone, trim the excess. To make the lid, an outline of the narrower end of midsection of stone flask was marked on a ceramic tile; thick mix of stone was poured on the tile. The surface was flattened and left to set. Later it was trimmed till the
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Making of the molds

Latex rubber is recommended for making the molds because of its ease of application and low cost. Place all the parts of the stone flask on a smooth, flat surface. Place the two flask models with the inside up. Do not use any separating media on the flask models. Paint latex rubber over each flask models. Let the first coat dry before applying the second coat. Apply 7-8 coats (Appendix 3). After the last coat of latex rubber sets, make a mixture of dental plaster and cover the latex rubber to a depth of about 10 mm to serve as a backing for the mold. After the gypsum sets, carefully separate the stone flask patterns from the latex to obtain the mold (Appendix 4).

used while making the bolt guide to create the screw holes for insertion of bolts [3]. Drill two holes through the top of the flask. Assemble all three parts of the fiberglass flask, insert the metal bolts. The flask is now ready for use (Appendix 6).

Discussion
This fibreglass flask can be made of any size even large enough to accommodate the processing of most large maxillofacial prosthesis. Fiber-reinforced plastic was used in making of these flasks, which act as a filler and allows it to accept the strenuous pressure when packing a denture along with the heat associated while microwave curing. Various sizes of fibreglass flask can be made with this technique. Different sizes of flasks can also be made using metal template as described by Mc Kinstry [3]. One of the major advantages of using this technique for making microwavable flasks is the cost. Flasks made by this technique are 10- 15 times cheaper than the commercially available microwavable flasks. Kimura [2] advocated the use of polycarbon bolts to avoid reflection of microwaves during processing. However polycarbon bolts expand during processing and they can break also. There is no detrimental effect from the use of metal bolts

Making of Fiberglass Flask

Mix the fiberglass liquid resin with the appropriate catalyst, and fiberglass fibers, to create thick slurry. With this fiberglass mixture, fill each of the three molds (Appendix 5) and cover each with a piece of glass plate. Allow 3 hours for the resin to harden and remove the gypsum backings from the latex molds. Remove the latex mold from fiberglass flask sections. Drill a hole of 3mm diameter in the middle of the bolt guide for the insertion of bolts using a power drill and complete the finishing of flasks. Even lubricated suction tips can be

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Table1. Few of the key features that differentiate the commercially available microwavable
dentures versus the custom made microwavable dentures. Commercially Available Microwavable Dentures
Can be used for only few denture processing. Costly Can be used for many denture processing Economical, it is around 10-15 times cheaper than the commercially available one. Fiber- reinforced plastic denture flask system Custom made (US Shizai Corp, Santa Monica, Calif) Curing large maxillo-facial prosthesis is difficult Curing large maxillo-facial prosthesis is possior not possible ble

Custom Made Microwavable Dentures

in microwave processing, and metal bolts do not expand. This was also reported by Mc Kinstry [3] and De Clerck [6]. Fiberglass, like all common forms of glass, is a chemically inert substance. However, exposure to these products may cause skin and eye irritation and the inhalation of fibers may irritate the upper respiratory tract in few people. As the solvents, compounds and resins used in making of fiberglass reinforced flask are mostly flammable; precautions should be taken during their mixing, use and storage.

Conclusion
This article describes a simple and economical procedure for making oversized microwavable flasks with the help of materials, which are easily available. These flasks are strong enough to withstand compression molding packing pressure along with the heat associated with microwave curing (Table 1).

List of abbreviations
There is no abbreviation.

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Conflicts of interests
The authors declare that they have no competing interest.

5. Neiman R. Gypsum products. In: Anusavice KJ, editors: Phillips science of dental materials, 10th edition. Harcourt Asia: Saunders, 2000; 185-209. 6. De clerck JP. Microwave polymerization of acrylic resins used in dental prosthesis. J Prosthet Dent 1987; 57: 650-8.

Acknowledgments
This study was not financially supported by any institution and commercial sources.

Authors' contributions
Main idea: by SD, RP. Literature search: by SD.
Data interpretation: by SD, ND. Manuscript preparation: by RP, ND.

Data collection: by SD, RP.

Funds Collection: N/A.

References
1. Nishii M. Curing of denture base resin with microwave irradiation with particular reference to heat-curing resins. J Osaka Dent Univ 1968; 2: 23-40. 2. Kimura H. Application of microwave for dental technique. Part I Dough- forming and curing of acrylics. J Osaka Univ Dent Sch 1983; 23: 43-9. 3. Mc kinstry RE. How to make microwavable denture flasks. J Prosthet Dent 1990; 63: 104-10. 4. Levin B, Sanders JL, Reitz P. The use of microwave energy for processing acrylic resins. J Prosthet Dent 1989; 61: 381-3.
This journal utilizes the LOCKSS system to create a distributed archiving system among participating libraries and permits those libraries to create permanent archives of the journal for purposes of preservation and restoration. Citation : Dhaded S, Prajapat R, Dhaded N. Innovative method for fabrication of microwavable denture flasks. Dent Hypotheses 2011; 2: 178-189. doi: 10.5436 /j.dehy. 2011. 2.00043
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Appendix 1. Thick mix of dental stone applied on the outer surface of brass flask.

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Appendix 2. Parts of the flask separated.

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Appendix 3. Latex rubber painted over the stone flask to make mold.

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Appendix 4. Mold of lower part of flask after dental stone flask has been separated.

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Appendix 5. Fiberglass mixture is filled in the mold of lower part.

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Appendix 6. Microwavable Fiberglass flask with metal bolts.

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