Lost wax

Technique
 Definition :
◼ Spruing is the procedure of attaching a sprue former to the wax
pattern.
◼ Sprue former is a wax , plastic/resin or metal pattern used to
form the channel allowing the molten metal to flow into the
mold to make a casting.
◼ Sprue channel is the passage or pathway between the crucible
and the mold cavity created by burnout of wax pattern.
 Functions of the sprue former :
1 Escape way for the molten wax pattern.
2 Pathway for the entrance of the molten alloy
into the mold cavity.
3 Used as a handle for the wax pattern to avoid
hand touching
4- It acts as a reservoir to compensate for the
solidification shrinkage, as the alloy within the
sprue, must remain molten slightly longer than
the alloy within the mold.
 Materials of sprue former:

1- Wax
2- Plastic
3- Metal
 1- Wax sprue former:

➢ Ready made wax available with different shapes and

diameters.

➢ It is preferred because it melts at the same time as the

pattern --- allows easy escape of the molten wax.
 2-Plastic/Acrylic sprue :
➢ Ready made solid or hollow plastic available in different
shapes and diameters.
➢ Because of its rigidity --- used in casting of large
restorations ( as multiunit FPDs and cast PDs) to
minimize wax pattern distortion.
➢ Hollowed one is preferable than the solid ??????????
➢ Hollow plastic sprue former permits the easy escape of
wax through the space.
➢ Solid plastic sprue former soften at a higher
temperature than the wax pattern and block the escape of
wax – casting roughness
Hollow plastic sprue former
 3- Metal sprue former:

➢ It is made of non-rusting (rust proof) metal ?

To avoid contamination of the alloy through its path to
fill the mold.
➢ If used should be removed after investing and before
wax elimination.
➢ When using the metal sprue former – coat its surface
with a layer of wax to allow its easy removal.
➢ Solid metallic sprue former not used anymore.

➢ Hollow metallic sprue former preferred than solid

one?
a. Transmits less heat to the wax pattern on attaching (less
distortion).
b. Better attachment with the wax pattern (more surface
area).
Sprue attachment (Location of sprue):

◼ The sprue former should be attached to the bulkiest non-

critical of the wax pattern; away from central fossa, fine
margins and functional cusps (Centric cusps).

◼ If the sprue is attached to a thin portion?? the

metal at this area will solidify early before the
filling of the rest of the mold (shrinkage porosity).
◼ In case of crown it is attached to the largest non-
functional cusp while in case of inlay the sprue is
attached to the marginal ridge.
➢ The sprue former should be attached to the wax
pattern when it is seated on the die to prevent
distortion.
➢ The sprue former is attached to the wax pattern
by a drop of sticky wax rather than heating the
sprue former?? to minimize the induced stresses
that when relifed will distort the pattern.
 ➢ One end of the sprue former is attached to
the wax pattern with a reservoir while the
other end is attached to the crucible former.

Wax pattern
Sprue former

Crucible former
➢ The attachment area should be flared (no acute
angle attachment) for smooth flow of molten alloy.

➢ The attachment area should not be restricted

(necking)??
➢ This interferes with escapement of molten wax.
➢ This decreases the casting pressure that reduces the
mold filling
 Diameter of the sprue former (size) :

◼ The sprue former should be slightly thicker than the

thickest part of the pattern??
◼ It acts as a reservoir to compensate for the solidification
shrinkage of the alloy; otherwise molten alloy will freeze in
the sprue before it freeze in mold, preventing more metal
from entering the mold.
◼ Proper selection of sprue former diameter???
✓ a- Improve the flow of molten alloy into the mold
✓ b- Act as a reservoir to compensate for the solidification
shrinkage
The selected diameter depend on:

1- The thickness of the wax pattern:

▪ 2.5mm (10-gauge) sprue is recommended for

molar and metal-ceramic patterns.

▪ 2mm (12-gauge) is recommended for premolars

and partial coverage restorations.
2- The casting technique:
A- Air-pressure casting technique:
- The alloy is melted in the depression created by the
crucible former and then forced into the mold by
compressed air or other gases as carbon dioxide or
nitrogen.
- A narrow (thin) sprue former prevents the molten
alloy from flowing into the mold prematurely.
B- Centrifugal casting technique:
- A wide (thick) sprue is used as the molten alloy is
casted in a very high speed and must pass in a
wide area to prevent the fracture of the
investment
Angulation of sprue attachment:

◼ The sprue former should attached with 45 degree to the

wax pattern --- easy escape of molten wax and flow of
molten alloy to be directed to all parts of the mold
cavity smoothly.

◼ Right angle attachment interfere with easy escape of

molten wax and allow turbulence during casting and the
subsequent formation of porosity.
Attachment at 45º Attachment at 90º
 Length of sprue former :
◼ The length of the sprue former is ranged from 2-6mm.

◼ It should be long enough to place the end of the

pattern at a suitable distance from the top end of the
ring??????????
◼ Too long sprue former ---- premature solidification of
molten alloy in the sprue before complete filling of the mold
+ thin investment bridge which may crack under casting
pressure leading to fin formation on the casting ,
incomplete casting or empty mold.
◼ Too short sprue former -- back pressure porosity

the mold will be far from the end of the ring and gases
within the mould cannot escape through the porous
investment.
➢ In case of gypsum bonded investment:
◼ The distance between the end of the wax pattern and
the top end of casting ring should be 6-8mm.

➢ In case of phosphate bonded investment :

◼ The distance between the end of the wax pattern and the
top end of casting ring should be 3-4mm --- as the
phosphate bonded investment is stronger and less porous.
◼ Sprue length should be adjusted to place the wax
pattern away from the center of the ring (the
hottest zone).
◼ While, the sprue former, reservoir and runner bar
are placed in the center of the ring --- keep the
alloy molten during casting --- continuous supply
of the molten alloy to the solidifying casting ----
compensates for the casting shrinkage.

Correct Incorrect
 Shape of the sprue former :

◼ The sprue former should be straight as possible

to lessen the chance of turbulence (increases the
porosity) as the alloy enters the mold.
1- Direct sprue:
✓ Directed towards the wax pattern
without any angulations.

2- Indirect sprue:
✓ Goes through different angles
along its path to the wax pattern.
Number of sprue former :

◼ The number is related to the size of the wax

pattern.
◼ The small crown needs single sprue, while
the large crown needs double sprues.

◼ In case of bridge, multiple sprue system is

used.
◼ Single direct sprue:
✓ Used in case of noble and high noble alloys.
◼ Single indirect sprue: (Zigzag shape)
✓ Used in case of non-precious alloys??????

✓ To give a chance for the oxide layer around the

molten non-precious alloy to attach to the walls
of the sprue channel -- molten alloy reaches the
mold with the least amount of oxides.
◼ Double direct sprue:
✓ It is shaped as V or Y.
✓ Used in case of noble and high noble alloys.

◼ Double indirect sprue:

✓ It is staple shaped sprue.
✓ Used in case of non-precious alloys
◼ Multiple direct sprue:
✓ It is shaped as main sprue with direct feeders
◼ Multiple indirect sprue:

✓ It is composed of:
◼ Main feeder sprue (thick sprue)
◼ Oblique sprues

◼ Horizontal stabilizing sprue (runner bar)

◼ Feeders (from the horizontal to the pattern)

◼ Accessory sprue (Auxiliary sprue) :
✓ It is used to improve the casting of the thin area in the
wax pattern.
✓ As the buccal surface in case of veneered crown to
prevent perforation of the surface due to incomplete
compensation for shrinkage of thin wall.
◼ Function:
1. Help the gases to escape during casting (venting).
2. Act as a reservoir to compensate for the solidification
shrinkage in the critical thin areas
Ring liner

Casting ring

Crucible
former
 Crucible former :
◼ It is the conical part that holds the sprue former
and the pattern during investing.
✓ It is available as plastic, metal or rubber

✓ It is removed before putting the ring into the

furnace for burn out of the wax.
C.S of invested wax pattern Casting ring after wax
in casting ring elimination
✓ Function :
1 Act as a base during pouring of the investment.
2Hold the wax pattern during setting of the investment.

3- Hold the casting ring.

4- When removed --- funnel depression in the investment

that guide the molten alloy to the mold through the
empty sprue channel.
 Preparation of the wax pattern :
◼ The wax pattern is sprayed with debubblizer (wetting
agent – surface tension reducer) and left until complete
drying to obtain a smooth surface restoration.
◼ Functions of the wetting agent (debubblizer):
1 It increases the wettability of the wax .
2 It gives better adaptation between the investment and the
wax pattern.
3 It gives a smooth casting with no roughness or nodules.
 Casting ring:

◼ The casting ring holds the investments during setting and

restrict its expansion.
◼ It is available as metal, plastic, rubber or paper.
◼ It is supplied in different sizes according to the size of the
wax pattern.
◼ The wax pattern should be centrally positioned in the
casting ring to allow for even amount of investment all
around and even expansion.
◼ The rigid ring ---- restrict the expansion of the
mold (used with precious alloys), while the
flexible ring ---- unrestricted expansion (used
with the non-precious alloys).
◼ The ringless casting using paper or plastic
tapered ring with phosphate bonded investment
when casting higher melting alloy to compensate
for high alloy shrinkage upon cooling (non-
precious alloys) (crucible former and ring is
removed after investment material has set and
before wax elimination).
 The ring liner:
◼ The inner surface of the ring is lined by resilient
lining material leaving about 2-3 mm from both
ends to allow contact between the investment
and the ring.
 Materials of ring liner:
1 Asbestos:
Its vapor is carcinogenic and not used anymore.
2 Paper like, made of a cellulose material:
Similar to paper with good water sorption.
3 Ceramic:
Refractory material with low water sorption
(need wetting agent).
 Functions:
1 Act as a cushion to allow investment expansion.
2 Direct the investment expansion outward-----
prevent wax distortion.
3Source of water for the hygroscopic expansion. 4-
Facilitate venting during casting procedure.

5- Facilitate the removal of the investment from the

ring after casting.