Technical Articles

Clinical technique, instrument science, and material-specific finishing protocols written for dental professionals.

Digital World

Simple Techniques For Creating a Monolithic Hybrid

Douglas Frye, C.D.T. — President, Functional Esthetics Dental Laboratory Inc., Farmington, Missouri

Now that the digital world has become a reality, let’s make the most of it. We are now receiving digital files for printing in-house models (fig. 1), or fabricating monolithic restorations from just the files themselves. With the modeless application, we have been limited to layering techniques for fabricating natural looking restorations. This is now changing...
The available products that can be milled in the dental office or in the laboratory are still changing in the industry. So why not fabricate a much more lifelike restoration following the Monolithic Hybrid Technique? It’s a simple two firing process for lithium disilicate or similar materials, that will set your restorations apart from others.

Once the restoration is designed, it then will be milled as a standard monolithic restoration (fig 2). I separate the milled restoration from the block with a ZR19mm diamond disc (fig.3). I use the same disc for contouring the interproximal line angles as well as the tooth formation, creating the ideal emergence. The sprue connector is quickly removed utilizing the diamond infused white section of the SRS 2 Step Sprue removal instrument (fig 4). The top section of the SRS instrument is a BlueBerry™. This top section smoothes the connector/restoration interface (fig 5). After sintering, I use a Diacool™ diamond infused instrument for bulk shaping. The abrasive nature of the Diacool™ is smooth and gentle, thereby eliminating the chipping which one might observe using other types of grinding materials.

The next step in fabrication of “Higher Quality Standard” restorations, is the ability to recreate the surface texture to simulate and mirror the surrounding dentition. The BlueBerry™ and RedBerry™ instruments assist in the contouring and smoothing of surfaces that will mimic the existing dentition. The RedBerry™ is my go–to instrument for bulk reduction. It safely reduces incisal length and helps to create ideal line angles (fig. 6). The BlueBerry™ contains a more subtle diamond. I use this for fine tuning surface texture and creating incisal irregularities for a more natural appearance (fig. 7). The restoration has now been shaped to the ideal size, where surface texture appears natural and mimics the surrounding dentition.

Now it is time to create the “Hybrid” cut–away. We are looking to replicate what is most commonly observed in natural dentition. We understand that color should come from within, rather than from externally placed stains that can produce unnatural results with regard to light diffusion and absorption.

Creating natural looking restorations is always our goal. To accomplish this, I use a Diacool™ 403 or 407 (fig. 8) to create small divots in the surface of the pre sintered restoration to allow for the ceramic material to be placed. The application of the ceramic material could either be with modifiers or internal staining techniques. I then place cuts at random places on the surface in order to create natural craze lines. (Craze lines are observed 85% of the time in natural dentition). The cuts are made with a ZR diamond disc on a 90° angle followed by cuts at a 45° angle (fig. 9). With surface blemishes in place, we can begin to consider the fast application of internal staining as part of the “Hybrid Technique” (fig. 10). These steps are done as a time saving technique prior to the sintering process.

Prior to the second and final firing, a case appropriate ceramic overlay is applied (fig.11). In this situation I used a transparent neutral incisal. Once retrieved from the porcelain furnace, a simple touch up with a silicone wheel (fig. 12), and diamond polishing compound, is all that is required to complete a natural looking restoration (fig. 13).

Douglas Frye pic Douglas Frye product1 Douglas Frye product2
Dental Technology

You Gotta Keep It Separated

Lucas T. Lammott, DTG — M31 Dental Studio

Aesthetics in dental technology is all about detail; whether it’s finessing a line angle, sharpening a cusp tip, or balancing symmetry with natural asymmetry. One of these often forgotten details, I believe, is interproximal separation of multi unit bridges. Proper separation with regard to function and aesthetics is essential. The correct balancing of shadow and reflection will bring a multi unit case to life with a natural, lifelike appearance...
Yes, you might think this is obvious dental technology 101, but you would be surprised by some larger cases I’ve seen with units that just seem to “run together.” I’ve seen this very same issue with many of the new zirconia hybrid bridges. Even the smallest burs from the most advanced milling machines do not have the ability to get in between those hard to reach places as much as we all would like. It’s not enough to simply let this go… it needs to be fixed before you sinter the case. Trying to open and create natural embrasures after sintering has taken place is too difficult and will most likely cause micro fractures in your zirconia.

By utilizing my simple technique you will save time, and eliminate the potential of creating micro fractures in your restorations.

The extremely flexible, super thin, knife edged instrument (GS 104), is perfect for opening up interproximals and embrasures without chipping or gouging your cutback, while being able to round your line angles and keep a natural contour. (fig. 1)

I use the diamond coated blade (GSBKIT), with a light sawing/scraping motion, that allows me to take the separation deeper and finer. This instrument has become absolutely essential in my small yet effective arsenal of zirconia instruments. (fig. 2)

Your zirconia is now ready for sintering. Remember, the objective for green state contouring is to reduce the number of adjustments and contour corrections often made in the sintered state. This will result in a much stronger, long lasting restoration for the patient, and less chance of you needing to remake the restoration. (fig. 3)

Lucas Lammott pic Lucas Lammott sign Lucas Lammott products
Widespread Acceptance

Getting the Most Out of Full Contour Zirconia

Bob Cohen, CDT — CAP (Custom Automated Prosthetics)

Through the widespread acceptance of CAD/CAM and full contour zirconia (FZ) restorations, it is important to understand the availability and advantages of zirconia specific rotary instruments. Utilizing the correct tools for processing milled green state zirconia, and the post sintered zirconia, provides an opportunity for product enhancement. Through the use of these zirconia specific rotary instruments, the availability of all needed tools is now complete. Now, let’s look at getting the most out of full contour zirconia...
Providing high end FZ restorations obviously begins with a great material, design and milling strategy. That said, there are significant enhancements one can add to the product using little time and some additional knowledge. Utilizing the best tools and materials will further enhance the product, and do so very efficiently. In fact, two of the primary reasons that zirconia is the fastest growing indirect restorative material, are cost and low labor.

For full contour zirconia, the analog process begins after the milled zirconia is removed from the disk. In the green state, zirconia is quite soft and easily trimmed. Adjustment of the extra margin thickness is accomplished with HE Silicone™ Carbide Infused wheels and points (fig.1). The GS Contour 2 step instrument may be used at the final connection point between the sprue and actual restoration. This leaves an ultra smooth surface. For refining embrasures, it is best to use a friction grip pointed diamond (ZD1C OR ZD2A, fig. 2) at a slower speed or the same shape in a hand piece slow speed tool (ZHP1C or ZHP2A–Ref HP chart). Additional green state adjustments or detailing such as subtle contouring, touching up occlusal anatomy, and surface texture can be easily added with the ZD2F or ZD1C (fig.3 & 4).

Historically, most green state zirconia is dipped into a shading material to obtain a monochromatic color that somewhat matches the desired shade after sintering to better enhance the FZ restoration. Once all final contouring is complete, a multi–coloring process can be utilized. Utilizing colorants for green state shading one can multi shade the FZ monolithic restoration (fig. 5). By nature, green state zirconia is quite absorbent. This absorbent property results in the colorants penetrating the surface of the material. By following the protocol one obtains the advantages of a monolithic restoration that is multi shaded.

Once sintered, all adjustments made with diamonds should be done with irrigation, so as to prevent introducing micro fractures into the restoration. First, crowns should be carefully tried on the die. Generally there is no adjustment needed. However, in the event of a prematurity, it is recommended to utilize a fit check paint or spray. Adjusting of axial walls or occlusal surface can be accomplished with a ZD1D high speed diamond and irrigation (fig. 6). Proximal contacts can be fine tuned and occlusal adjustments can be accomplished with a 1 mm round high speed diamond (ZD4D). Due to the hardness of zirconia it is critical to polish the surface of the restoration prior to final stain and glaze. Zirconia manufactured for dental is extremely homogeneous. This results in a surface that can be polished to a super smooth surface. For final contouring it is recommended to use a RedBerry™ (Coarse) followed by BlueBerry™ (Medium) and GoldenBerry™ for high shine polishing (fig.7). The Berrys actually leave a smooth surface as they reduce and contour. These instruments are also available in points for high shine polishing occlusal detail. Final stain and glaze may be accomplished with polishing compound.

Once the crown is delivered to the dentist it is just as important that any pre and or post insertion adjustments made by the dentist are also polished. The Wagner dentist ZR / LD chair side adjustment kit contains all the necessary tools for final intra oral adjustment and polishing.

With proper handling of zirconia by both the laboratory and dentist, these super high strength materials will offer patients years of service working in harmony with existing dentition.

Bob-Cohen pic Bob-Cohen product
Fast Growing

Steps to Zirconia Completion

Step Bay, CDT, DTG — CDI Science

Thanks to fast growing CAD/CAM and material technologies advancing so quickly, technicians are able to take more control over the lab production process; and at a lower price than previously thought possible. The demand for these new harder materials is growing at a remarkable pace, so now is not the time to fall behind. Getting the most from these new materials and processes requires new specialized instruments. Wagner Precision Rotary Instruments provides the solution, with the high quality of German manufacturing, and the cost effectiveness of better diamond engineering which makes for faster work, longer lasting instruments, and no harmful heat production...
I have found that there is an increase in the number of dentists that want full contour zirconia restorations. This material’s strength, in the posterior region, is a great advantage, and the demand for polished monolithic zirconia crowns is on the rise.

Studies have shown that the monolithic zirconia crown, with a mechanically polished surface, has less enamel wear than a feldspathic crown. So, zirconia also appears to be more beneficial in terms of antagonistic tooth wear.

With this knowledge, I began designing zirconia linguals on my anterior bridges. It’s a similar concept to a metal lingual, but crafted entirely from zirconia. The following case is a documentation of a zirconia bridge with a fully supported lingual. The specialized rotary instruments I used, make this technique possible in an easy, efficient, and low-cost way.

Zirconia connectors are seperated by using a ZHP 2C (fig.1). This thin diamond tip which barely vibrates is ideal for the task. The ZHP 1A is a thicker diamond, and I like to use this on the awkward areas in between the margin and the sprue. The 501 silicone wheel (fig.2) easily removes the sprue and flash.

The unique two-step GS Contour has a bold gray area and a white tip. This revolutionary instrument smoothes and polishes the zirconia in the green state, with the fine (gray) smoothing area (fig.3) and superfine (white) polish area (fig.4). After sintering, I cut the connectors with a ZR 19mm x0.26mm disc (fig.5) and smooth out the surface with a Diacool™ and a BlueBerry™ (fig.6 & 7). The ZR diamond disc has uniquely shaped particles and is multi-layered; it’s more effective than a traditional diamond disc. The Diacool™ removes a greater amount of excess material, while the BlueBerry™ actually smoothes the restoration as it contours. It’s an interestingly unique instrument.

The comparison shows #7 finished with the GS Contour and a GoldenBerry™, resulting in a much better shine than #8-10, done with a series of standard medium and high shine polishing instruments (fig.8).

Step Bay pic Step Bay product Step Bay product
Finishing Time

On the RA Latch Berrys

Carlos Sanchez, DDS, FAGD, PA — Product testimonial

In looking for instruments that minimize my finishing time, while achieving harmonious integration of the composite resin with existing tooth structure, I came across the “RA Latch Berrys.” They have become my primary armamentarium for preparation, finishing, and polishing my nano hybrid composite, as well as my zirconia restorations...
I use the friction grip diamonds to prepare and contour my restorations. Initial polishing is quickly accomplished with the RedBerry™ and BlueBerry™. I obtain a final super gloss with GoldenBerry™ finishing cups and points.

The combination of these instruments provides a multifunctional, efficient system for preparing teeth and then contouring, shaping, and polishing the final restorations.

Carlos Sanchez pic Carlos Sanchez product

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