Ivoclar Vivadent IPS e.max ZirPress User Manual
ZirPress
all ceramic
all you need
I N S T R U C T I O N S F O R U S E
Table of Contents
3 IPS e.max System – one system for every indication
ZirPress
PR OD UC T
IN FO RM ATI ON
4 Product Information
Material
Uses
Composition
Scientific Data
Ingot Concept
8 Clinical Steps, Framework Preparation, Contouring, Pressing Procedure
Overview of the Fabrication Procedure
Shade Determination – Tooth Shade and Shade of the Prepared Tooth
Preparation Guidelines
Fabrication of the IPS e.max ZirCAD Framework
Application of IPS e.max Ceram ZirLiner
Contouring
Sprueing, Investing
Preheating, Pressing
Divesting, Removal of the Reaction Layer
31 Staining Technique
Finishing
Stain and Characterization Firing
Glaze Firing
36 Cut-Back Technique
Finishing
Veneering with IPS e.max Ceram
42 Layering Technique
Finishing
Veneering with IPS e.max Ceram
47 Gingiva Technique
Framework Design Criteria
AP PL IC ATI ON P RO CE DU RE
Framework Preparation and Application of IPS e.max Ceram ZirLiner
Contouring
Sprueing, Investing
Veneering with IPS e.max Ceram
56 Abutment Technique – Pressing on the Straumann®Anatomic IPS e.max®Abutment
Application of IPS e.max Ceram ZirLiner
Contouring
Sprueing, Investing
Preheating, Pressing, Divesting
Finishing
Stain and Characterization Firing
Glaze Firing
65 Seating and Follow-Up Care
Possibilities for Cementation
Preparing for Cementation
Care notes
-
IN FO R
MAT IO N
ZirPress
68 General Information
Frequently Asked Questions
Materials Combination Table
Press and Firing Parameters
2
®
e.max
IPS
System
all you need
IPS e.max – one system for every indication
IPS e.max is an innovative all-ceramic system which covers the entire all-ceramic indication range – from
Thin Veneers to 12-unit bridges.
IPS e.max delivers high-strength and highly esthetic materials for the Press and the CAD/CAM
technologies. The system consists of innovative lithium disilicate glass-ceramics used mainly for singletooth restorations and high-strength zirconium oxide for large-span bridges.
Every patient situation presents its own requirements and objectives. IPS e.max meets these requirements,
because due to the system components you obtain exactly what you need.
– The components for the Press technology include the highly esthetic IPS e.max Press lithium disilicate
glass-ceramic ingots and the IPS e.max ZirPress fluorapatite glass-ceramic ingots for the fast and
efficient press-on-zirconia technique.
– Depending on the case requirements, two types of materials are available for the CAD/CAM
technique: the innovative IPS e.max CAD lithium disilicate glass-ceramic blocks and the IPS e.max
ZirCAD high-strength zirconium oxide.
– The nano-fluorapatite layering ceramic IPS e.max Ceram, which is used to characterize/veneer all
IPS e.max components – glass or oxide ceramics –, complete the IPS e.max System.
IPS e.max ZirPress
The shades and translucency levels of the IPS e.max ZirPress ingots are based on the overarching
IPS e.max shade system. The system has a flexible design and can be used in conjunction with the A–D,
Chromascop as well as Bleach BL shade guides.
The shades of the Press ingots and CAD/CAM blocks offered in the IPS e.max System are all coordinated
with each other. They are available in different degrees of opacity and/or translucency. The selection of
the translucency level is based on the clinical requirements (shade of the prepared tooth, desired tooth
shade) presented by the patient, as well as the desired processing technique (layering, cut-back, staining
technique).
The more opaque MO ingots are predominantly suitable for the layering technique, while the more
translucent LT and HT ingots are used for the cut-back and also the staining technique.
3
®
e.max
IPS
ZirPress
Product Information
Material
IPS e.max ZirPress is a fluorapatite glass-ceramic ingot
which is pressed onto
zirconium oxide. Since the
fluorapatite crystals are
present in various sizes, the interplay of translucency, opalescence,
and brightness can be controlled in a targeted fashion and thus
results in optimum masking of the less translucent zirconium oxide
frameworks.
In the press-over technique, the advantages of the PRESS technology
(accuracy of fit) are optimally combined with those of the CAD/CAM
technology (processing of zirconium oxide). IPS e.max ZirPress is
suitable to press over IPS e.max ZirCAD single-tooth and multi-unit
bridge frameworks as well as ZrO2abutments. With minimum
technical effort and in a short time, the tried-and-tested PRESS
technology is used to press on the IPS e.max ZirPress ingots.
Frameworks pressed over with IPS e.max ZirPress demonstrate firingstable ceramic shoulders with excellent accuracy of fit and may
subsequently be efficiently characterized or veneered using
IPS e.max Ceram. In this way, esthetic and highly functional
zirconium oxide-support restorations are fabricated in accordance
with the customer’s needs and in an economical fashion.
With the use of IPS e.max ZirPress Gingiva, the press-over technique
can be used to fabricate exact, homogeneous gingival areas
particularly for larger restorations.
CTE (100-400°C) [10-6/K] 9.8
CTE (100-500°C) [10-6/K] 9.9
Flexural strength (biaxial) [MPa]* 110
Vickers hardness [MPa] 5400
Chem. solubility [µg/cm2]* 30
Press temperature [°C/°F] 900–910/1652–1670
*according to ISO 6872
Uses
Indications
– Pressing over IPS e.max ZirCAD single-tooth frameworks
– Pressing over multi-unit IPS e.max ZirCAD bridge frameworks
– Pressing over IPS e.max ZirCAD inlay-retained bridge frameworks
– Pressing over implant superstructures made of IPS e.max ZirCAD
(single-tooth and bridge frameworks)
– Pressing over Straumann®Anatomic IPS e.max®Abutments
– Pressing over frameworks, implant abutments and implant super-
structures made of sintered zirconium oxide and/or HIP zirconium
oxide with a CTE range of 10.5–11.0 x 10-6K-1(100–500 °C/
212–932 °F).
– Veneers
Contraindications
– Pressing over zirconium oxide frameworks with a CTE outside the
stipulated range
– Pressing over non-sintered zirconium oxide frameworks
– Very deep sub-gingival preparations
– Patients with substantially reduced residual dentition
– Bruxism
– Bridges with more than one extension unit
– Any other use not listed in the indications
Important processing restrictions
Failure to observe the following restrictions may compromise the
results achieved with IPS e.max ZirPress:
– Failure to observe the necessary IPS e.max ZirCAD minimum
connector and framework thicknesses
– IPS e.max ZirPress ingots must not be pressed on the zirconium
oxide framework without prior application of IPS e.max Ceram
ZirLiner
– Pressing the IPS e.max ZirPress ingots without zirconium oxide
frameworks (except for veneers)
– Layering with a veneering ceramic other than IPS e.max Ceram
– Failure to observe the necessary minimum thicknesses for pressed
ceramics
– Exceeding the maximum thicknesses for pressed ceramics
– Pressing over metal frameworks
– Pressing over zirconium oxide frameworks for which the manu-
facturer’s instructions regarding minimum framework and
connector thicknesses have not been observed
Side effects
If the patient is known to be allergic to any of the components
of IPS e.max ZirPress, the material must not be used to fabricate
restorations.
4
Composition
The IPS e.max ZirPress ingots and the corresponding processing accessories consist of
the following main components:
– IPS e.max ZirPress ingots
Components: SiO
Additional components: Li2O, Na2O, K2O, MgO, Al2O3, CaO, ZrO2, P2O5and other
oxides
– IPS Alox Plunger
Components: Al2O
– IPS Alox Plunger Separator
Components: Boron nitride
– IPS e.max Press Invex Liquid
Components: Hydrofluoric acid and sulphuric acid in water
– IPS Natural Die Material
Components: Polyester urethane dimethacrylate, paraffin oil, SiO2and copolymer
– IPS Natural Die Material Separator
Components: Wax dissolved in hexane
2
3
– IPS PressVEST Powder
Components: SiO2, MgO and NH4H2PO
4
– IPS PressVEST Liquid
Components: Colloidal silicic acid in water
– IPS PressVEST Speed Powder
Components: SiO2, MgO and NH4H2PO
4
– IPS PressVEST Speed Liquid
Components: Colloidal silicic acid in water
Warning
– Hexane is highly flammable and detrimental to health. Avoid contact of the material
with skin and eyes. Do not inhale vapours and keep away from sources of ignition.
– Do not inhale ceramic dust during finishing – use exhaust air discharge and dust
mask.
– IPS e.max Press Invex Liquid contains hydrofluoric acid. Contact with skin, eyes and
clothing must be prevented at all costs, since the material is extremely toxic and
corrosive. The liquid is intended for professional use only and must not be applied
intraorally (inside the mouth).
5
Scientific Data
Further scientific data (i.e. strength, wear, biocompatibility) are contained in the ”Scientific
Documentation IPS e.max ZirPress”. The Documentation also provides a set of studies that describe the
clinical performance of IPS e.max ZirPress.
This Scientific Documentation can be obtained from Ivoclar Vivadent.
For further information about all-ceramics in general, please refer to the Ivoclar Vivadent Report No. 16
and 17.
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6
Ingot Concept
IPS e.max ZirPress ingots are available in three levels of translucency (HT, LT, MO) and one size. For the fabrication
of gingival areas, e.g. for implant superstructures IPS e.max ZirPress Gingiva ingots are available.
From a processing point of view, basically all restorations can be fabricated of any ingot. For reasons of esthetics, however,
the following processing technique and indication are recommended for the individual ingots (translucency levels):
Translucency Level
High
Translucency
Low
Translucency
Medium
Opacity
Gingiva
CR %
Processing Technique
taining
S
Technique
ut-Back
C
Technique
ayering
L
Technique
Pressing without
ramework
rO
f
Z
2
eneers
V
ingle-Tooth
S
Frameworks
Anterior and
(
osterior Teeth)
P
Pressing over frameworks made of ZrO
ulti-Unit
M
Bridge
rameworks
F
mplantat
I
Abutments/
uperstructures
S
Inlay-Retained
Bridge
Frameworks
2
ingival Areas
G
IPS e.max ZirPress HT (High Translucency)
The ingots are available in 16 A-D and 4 Bleach BL shades. Given their high translucency they are ideally suitable for fully
anatomical pressing over zirconium oxide frameworks (staining technique). The Characterization and Glaze firing is
subsequently conducted using IPS e.max Ceram Shades, Essence and Glaze materials. If adjustments are required, the
IPS e.max Ceram layering materials can be used.
IPS e.max ZirPress LT (Low Translucency)
The ingots are available in 16 A-D and 4 Bleach BL shades. Given their high translucency they are ideally suitable for the
cut-back technique, but also for the staining technique. The cut-back is subsequently supplemented with IPS e.max Ceram
Incisal and/or Impulse and characterized using IPS e.max Ceram Essence and Shades.
IPS e.max ZirPress MO (Medium Opacity)
The ingots are available in 9 A-D and 4 Bleach BL shades. Given their opacity they are ideally suitable for pressing a
dentin core or shoulder on zirconium oxide frameworks. The anatomical shape is subsequently individually layered using
ISP e.max Ceram. Finally, the Stain/Glaze firing with IPS e.max Ceram is conducted.
IPS e.max ZirPress Gingiva
The ingots are available in 2 shades (G3 and G4). In particular, they are ideally suitable for implant superstructures in order
to press voluminous gingival areas on the zirconium oxide framework. The actual layering of the restoration is conducted
with IPS e.max Ceram layering materials with the exact accuracy of fit of the gingival area being maintained.
7
®
e.max
IPS
ZirPress – Clinical Steps, Framework
Preparation, Contouring, Pressing Procedure
Working step
Practice
Shade Determination, Preparation, Shade of
the Prepared Tooth, Impression Taking
Framework fabrication
Contouring and Investing
Laboratory
Pressing
Ivoclar Vivadent Products
OptraGate,
IPS Natural Die Material
IPS Contrast Spray Labside
IPS e.max ZirCAD
IPS Investment Ring System 100 g, 200 g, 300 g
IPS PressVEST, IPS PressVEST Speed
IPS e.max Press
Programat EP 3000, EP5000
IPS Alox Plunger
IPS Alox Plunger Separator
IPS One-Way Plunger 300 g
Staining
Technique
Preparing for Cementation
Checking the Articulation/Occlusion
Cut-Back
Technique
Glazing
Cementation
Layering
Technique
IPS e.max Ceram Layering Materials
IPS UniTray
Programat P300, P500, P700
IPS e.max Ceram Glaze Paste, Powder
IPS e.max Ceram Glaze Spray
IPS e.max Ceram Essence, Shade
IPS Ceramic Etching Gel
Monobond Plus
OptraGate
OptraDam
Variolink II, Variolink Veneer
Multilink Automix
SpeedCEM
Vivaglass CEM
bluephase
OptraFine
Recall
Proxyt
The range of available products may vary from country to country
8
Shade Determination – Tooth Shade, Shade of the Prepared
Tooth
Optimum integration in the oral cavity of the patient is the prerequisite for a true-to-nature all-ceramic
restoration. To achieve this, the following guidelines and notes must be observed by both the dentist
and the laboratory.
The overall esthetic result of an all-ceramic restoration is influenced by the following factors:
• Shade of the preparation (natural preparation, core build-up, abutment, implant)
• Shade of the restoration (framework shade, veneer, characterization)
• Shade of the cementation material
The optical effect of the preparation shade must not be underestimated during the fabrication of highly
esthetic restorations. For that reason, the shade of the preparation should be determined together with
the desired tooth shade in order to select the suitable block. Especially with severely discoloured
preparations or non-tooth-shaded build-ups, this is of utmost importance. Only if the dentist determines
the shade of the preparation and its subsequent transmission to the laboratory may the desired esthetics
be achieved in a targeted fashion.
Clinical Steps, Framework Preparation, Contouring, Pressing Procedure
Preparation Shade
– Prepared natural tooth
– Core build-up
– Implant, abutment
Desired Tooth Shade
Cementation Material
Responsibility of the Dental Office Responsibility of the Laboratory
Shade determination of the natural tooth
After tooth cleaning, the tooth shade of the non-prepared tooth and/or the adjacent teeth is
determined with the help of a shade guide. Individual characteristics have to be considered when
determining the tooth shade. If a crown preparation is planned, for example, the cervical shade should
also be determined. In order to achieve the best possible true-to-nature results, shade determination
should be carried out at daylight. Furthermore, the patient should not wear clothes of intensive colours
and/or lipstick.
Restoration Shade
Framework
–
– Veneer
– Characterization
Die shade selection
In order to facilitate the reproduction of the desired tooth shade, the shade of the preparation is
determined with the help of the IPS Natural Die Material shade guide. This enables the technician to
fabricate a model die similar to the preparation of the patient, on the basis of
which the correct shade and brightness values of the all-ceramic restorations
may be selected.
9
Preparation Guidelines
1.0
1.2
1.0
1.2
1.5
1.0
1.2
1.5
1.0
1.0
1.2
1.5
1.2
6°
1.0
Successful results can only be achieved with IPS e.max ZirPress/ZirCAD if the guidelines and layer thicknesses are strictly
observed.
Basic preparation guidelines for all-ceramic restorations
– no angles or sharp edges
– shoulder preparation with rounded inner edges and/or chamfer preparation
– the indicated dimensions reflect the minimum thickness for IPS e.max restorations
– the radius of the preparation edges, particularly for anterior teeth, should be at least 1.0 mm (milling tool geometry) in
order to permit optimum milling during CAD/CAM processing
Single Crowns to 3-Unit Bridges
– Evenly reduce the anatomical shape and observe the stipulated minimum thickness. prepare a circular shoulder
with rounded inner edges or a chamfer of a width of at least 1.0 mm.
– Reduce the incisal crown third – incisal and/or occlusal – by approx. 1.5 mm.
– For anterior crowns, the reduction in the labial and/or palatal/lingual area is at least 1.2 mm. The incisal edge of
the preparation should be at least 1.0 mm (milling tool geometry) in order to permit optimum milling of the
incisal area during CAD/CAM processing.
– For posterior crowns, the reduction in the buccal and/or palatal/lingual area is at least 1.2 mm.
– For conventional and/or self-adhesive cementation, the preparation must demonstrate retentive surfaces.
10
1.0
1.5
1.0
1.5
2.0
1.0
1.5
2.0
1.0
1.0
1.5
2.0
1.5
6
°
Multi-Unit Bridges
– Evenly reduce the anatomical shape and observe the stipulated minimum thickness. Prepare a circular shoulder
with rounded inner edges or a chamfer of a width of at least 1.0 mm.
– Reduce the incisal crown third – incisal and/or occlusal – by approx. 2.0 mm.
– For anterior crowns, the reduction in the labial and/or palatal/lingual area is at least 1.5 mm. The incisal edge of
the preparation should be at least 1.0 mm (milling tool geometry) in order to permit optimum milling of the
incisal area during CAD/CAM processing.
– For posterior crowns, the reduction in the buccal and/or palatal/lingual area is at least 1.5 mm.
– For conventional and/or self-adhesive cementation, the preparation must demonstrate retentive surfaces.
Clinical Steps, Framework Preparation, Contouring, Pressing Procedure
11
Framework Fabrication – IPS e.max ZirCAD
The individual steps for the fabrication of a framework of IPS e.max ZirCAD are described below. The
complete procedure for the processing of IPS e.max ZirCAD is described in the IPS e.max ZirCAD Instructions
for Use.
If a ZrO2framework of an other manufacturer is used, the corresponding recommendations regarding processing
must be observed.
Layer thicknesses
The framework design is key to the success of durable all-ceramic restorations. The more attention is given to the framework design, the better the final results and the clinical success will turn out to be.
The following basic guidelines have to be observed:
– The IPS e.max ZirCAD framework material is the high-strength component of your restoration and must be
given a design that supports the overall shape of the restoration and the cusps.
– The excess in available space (severely prepared teeth, atrophied alveolar ridge) must be compensated by
corresponding framework dimensions and not by the pressed material.
– The parameters stored in the respective software are considered guidelines and have to be adjusted
according to the total thickness of the restoration using the available software tools.
– If possible, the connector design should be extended in the vertical direction, rather than in the horizontal direction.
Since the necessary connector dimensions cannot always be established in the sagittal (lingo-vestibular) directions, the
connector dimensions should always be expanded in the vertical (inciso-cervical) direction.
– A reduction in framework thickness always means a reduction in strength.
The following minimum thicknesses have to be observed for the framework design with IPS e.max ZirCAD (sintered):
Please note: The minimum dimensions of the IPS e.max ZirCAD framework must be 25% larger before sintering.
Anterior Region
Minimum
framework
thickness
Connector dimensions
Design type
circular
Posterior Region
Minimum
framework
thickness
Connector dimensions
Design type
circular
occlusal
incisal
Crowns
0.5 mm
0.7 mm
–
Crowns
0.5 mm
0.7 mm
–
Splinted crowns
0.5 mm
0.7 mm
2
7 mm
Supporting the tooth shape and/or gingiva (incisal, occlusal and/or basal)
Splinted crowns
0.5 mm
0.7 mm
2
9 mm
Supporting the tooth shape and/or gingiva (incisal, occlusal and/or basal)
3-Unit Bridges
0.5 mm
0.7 mm
2
7 mm
3-Unit Bridges
Inlay-retained bridges
0.5 mm
0.7 mm
2
9 mm
4-12-unit bridges with
2 pontics
0.7 mm
1.0 mm
2
9 mm
4-12-unit bridges with
2 pontics
0.7 mm
1.0 mm
2
12 mm
The IPS e.max ZirCAD framework must be designed in such a way that the following layer thicknesses can be observed
during the contouring for pressing on IPS e.max ZirPress:
– In order to ensure the desired tooth and gingiva shades as well as pressability, a minimum thickness of
0.7 mm must be observed.
– Unsupported press and layering ceramics must not
exceed a total thickness of 2.5 mm.
Cantilever bridges with
1 pontic
0.7 mm
1.0 mm
2
12 mm
Cantilever bridges with
1 pontic
0.7 mm
1.0 mm
2
12 mm
Failure to observe the stipulated framework design criteria and minimum thicknesses may result in clinical failures, such as
cracks, delamination and fracture of the restoration.
12
Framework Design Criteria
The framework design must always support the shape of the restoration as well as the cusps.
Anterior and Posterior Crowns
orrect
c
wrong
Bridges
orrect correct correct
c
wrong
wrong wrong
Clinical Steps, Framework Preparation, Contouring, Pressing Procedure
correct
Always observe the relation between width and height as well as
the suitable dimensions when designing the connectors.
Basically, the following applies: Height ≥ Width
wrong
Height ≥ Width
Width
13
Preparation of the IPS e.max ZirCAD framework (after sintering)
Adjustments of sintered IPS ZirCAD frameworks should be kept to a minimum (fine adjustment of the edges).
− For the selection of the grinding instruments, please refer to the Ivoclar Vivadent Flow Chart ”Recommended grinding
tools for IPS e.max zirconium oxide”.
− Finishing is carried out at low pressure, since too much pressure may result marginal chipping and local phase transition.
− Place IPS e.max ZirCAD framework on the model, check fit and make slight adjustments, if necessary.
− Do not ”post-separate” the bridge framework with separating disks after sintering. This may result in undesired predetermined breaking points, which will subsequently compromise the stability of the all-ceramic restoration.
− Check marginal areas and slightly finish, if necessary.
− For the fabrication of a pressed shoulder, the edges may be reduced up to the inner edge of the chamfer or shoulder
preparation.
− Make sure that the minimum thicknesses are maintained even after the minor adjustments.
− Before veneering, clean the framework with running water or the steam jet and dry.
− Do not blast the framework with Al2O3or glass polishing beads, since this may damage the surface.
Use the grinding instruments specifically developed for ZrO2to carry out the required
adjustments.
Completely sintered and finished IPS e.max ZirCAD framework.
14
Regeneration firing (optional)
Basically, adjustments of sintered IPS ZirCAD frameworks should be kept to a minimum.
A Regeneration firing is only recommended after:
– large-scale adjustment of the IPS e.max ZirCAD framework (e.g. reduction of cusps and overall thickness)
– use of grinding instruments not listed in the IPS e.max grinding tool recommendations.
– grinding with diamond grinding tools (graining >100 µm).
Please note:
Fractures or cracks in the IPS e.max ZirCAD framework caused by rough finishing, e.g. blasting with high pressure, cannot
be “healed” by a Regeneration firing.
A Regeneration firing should be conducted in order to
reverse changes in the sintered ZrO
due to an abrasive
2
finishing (see above). Please observe the following procedure
for conducting the Regeneration firing:
– Clean and dry the framework with a steam jet.
– Position the framework on metal pins on a honey-combed
tray.
– Conduct the Regeneration firing in a ceramic furnace (e.g.
Programat P700) using the respective parameters.
– As an option, a regular sinter firing in the Sintramat
(Program P1) can be conducted again. In this case,
position the object on ZrO2beads (not on a honeycombed tray)
Clinical Steps, Framework Preparation, Contouring, Pressing Procedure
Firing parameters for the IPS e.max ZirCAD Regeneration firing in the ceramic furnace
Furnace
B
°C/°F
min
S
t
À
1
°C/°F/min
T
°C/°F
1
H
min
1
L
°C/°F
t
°C/°F/min
À
P300
P500
P700
EP 3000
403
757
0:18
65
117
1050
1922
15:00
750
1382
25
45
EP 5000
P80
P100
P200
EP 600
PX1
403
757
403
757
0:18
0:30
65
117
65
117
1050
1922
1050
1922
15:00
15:00
750
1382
750
1382
––
––
12 min
– Do not adjust the framework by grinding after the Regeneration firing.
– Do not blast the framework with Al2O3or glass polishing beads before veneering, since this may cause lasting damage
to the surface.
15
Application of IPS e.max Ceram ZirLiner
IPS e.max Ceram ZirLiner must always be applied prior to the wax-up to achieve a sound bond between the framework
and the material pressed onto it. With the application of the ZirLiner, the framework shade and fluorescence are adjusted
to the desired tooth shade.
Direct press-on procedures on IPS e.max ZirCAD frameworks without using ZirLiner results in a poor bond and may lead to
delamination. Do not blast the framework with Al2O3or glass polishing beads, since this may damage the surface.
– Clean the IPS e.max ZirCAD framework with the steam jet before the application of the IPS e.max Ceram ZirLiner.
– Mix the IPS e.max Ceram ZirLiner in the desired shade with the respective IPS e.max Ceram ZirLiner Build-Up Liquid to a
creamy consistency.
– For shaded zirconium oxide frameworks, use IPS e.max ZirLiner clear.
– If a different consistency is desired, IPS e.max Ceram Build-Up Liquid (allround or soft) as well as the IPS e.max Ceram
Glaze and Stain Liquids (allround or longlife) may be used. The liquids may also be mixed with each other at any mixing
ratio.
– Apply ZirLiner on the entire framework, paying special attention to the margins. If required, the restoration may be
vibrated until an even, greenish colour effect is achieved. If the colour appears too pale, the layer is too thin.
– For more intensively shaded areas, four IPS e.max Ceram Intensive ZirLiners (yellow, orange, brown, incisal) are available.
– After that, the applied ZirLiner is dried.
– Conduct the firing on a honey-combed firing tray.
– After firing, the IPS e.max Ceram ZirLiner should exhibit a layer thickness of approx. 0.1 mm.
Before veneering, clean the framework with the steam jet. Do not blast the framework with Al2O3or glass polishing beads.
Mix the corresponding ZirLiner with IPS e.max Ceram ZirLiner Liquid to a creamy consistency. Cover the entire framework with ZirLiner.
16
IPS e.max Ceram Intensive ZirLiner can be used to design intensively shaded areas. The fired ZirLiner shows a homogeneous, silky-mat surface.
Firing parameters for the IPS e.max Ceram ZirLiner firing
IPS e.max Ceram on IPS e.max ZirPress
irLiner firing before wax-up and pressing 403/757 4:00 40/72 960/1760 1:00 450/842 959/1758 0
Z
B S tÀ T H V1 V2 L
°C/°F min. °C/°F/min. °C/°F min. °C/°F °C/°F °C/°F
Firing process for zirconium oxide-supported restorations
In order to obtain optimum firing results for IPS e.max Ceram, the following points have to be observed:
– In order to ensure an even thickness of the veneer, the zirconium oxide framework must be designed in such a way that
it supports the cusps. Depending on the clinical situation, the results are different wall thicknesses and dimensions of
the framework.
– Since ZrO2is a poor heat conductor compared to other framework materials, a low temperature increase rate tÀ is
required. This ensures even heat distribution in the bonding area between the framework and the veneer as well as the
outer surfaces of the restoration even with different framework thicknesses. In this way, an optimum bond as well as
even sintering of the layering materials are achieved.
– During cooling of the restorations after firing, stress occurs as a result of the different cooling speed at the outside and
within the material. With long-term cooling L for the “final firing cycle” this stress can be reduced and the risk of
delamination minimized, particularly in ZrO2-supported restorations.
Notes on cooling after completion of the firing program
In order to ensure “smooth” cooling of the restoration after firing, please observe the following notes:
– Wait for the acoustic signal or optical indication of the furnace at the end of the firing cycle before the firing tray with
the fired objects is removed.
– Do not touch the hot objects with metal tongs.
– Allow the objects to cool to room temperature in a place protected from draft.
– Do not blast or quench the objects.
Clinical Steps, Framework Preparation, Contouring, Pressing Procedure
17
Contouring
– In order to check the wax thickness after contouring, measure the ZirCAD framework with a sensor and record the
values.
– Weigh the IPS e.max ZirCAD framework with the fired IPS e.max Ceram ZirLiner and record the weight. The weight is
used to determine the wax weight after contouring. The wax weight is used to determine the number of required
ingots.
easure and record the framework thickness including the fired ZirLiner. Weigh the ZirCAD framework with the fired ZirLiner and record the weight.
M
Contour the restoration in accordance with the desired processing technique (staining, cut-back or layering technique).
Please observe the following basic guidelines:
– Isolate the plaster dies with a commercial plaster-wax separator.
– Use only organic waxes for contouring, since they fire without leaving residue.
– Secure the framework on the model in the correct position and attach the margins with wax.
– Exactly contour the restoration, particularly in the area of the preparation margins. Do not over-contour the preparation
margins, since this would require time-consuming and risky fitting procedures after pressing.
– For fully anatomical restorations, the possible occlusal relief must be taken into consideration as early as during the wax-
up, since the application of the Stains and Glaze results in slight increase in vertical dimensions.
Observe the following minimum and maximum layer thicknesses during contouring for pressing IPS e.max ZirPress.
– In order to ensure the desired tooth shade as well as complete pressing, a minimum thickness of 0.7 mm must be
observed.
– Unsupported press and layering ceramic components must not exceed a total thickness of 2.5 mm.
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1. Contouring for the staining technique
Design the restoration to full anatomical contour so that only requires glazing and, if necessary, characterization after
pressing.
Fully anatomical wax-up made of organic wax on the IPS e.max ZirCAD framework. Observe the minimum and maximum layer thicknesses! Check the occlusal contact points.
Tip
An acrylate polymer block IPS AcrylCAD that fires without leaving residue can be used
instead of modelling wax. An anatomically shaped component is created with the
inLab®System (Sirona) and waxed onto the zirconium oxide framework.
2. Contouring for the cut-back technique
In a first step, the restoration is given fully anatomical contours. Then, the cut-back of the wax-up (before investment) is
carried out. As an alternative, the cut-back may also be performed after pressing. In this way, the cut-back technique
enables the fabrication of highly esthetic restorations in a very efficient manner.
Secure the ZirCAD framework on the die, attach margins with wax and build-up the shape.
Reduction of the oral surfaces is not required
Clinical Steps, Framework Preparation, Contouring, Pressing Procedure
The following points should be observed for the reduction of
the wax-up:
– Reduce the contouring in the incisal third
– No design extreme mamelons (points and edges)
– Check the cut-back with a silicone key
– The minimum thicknesses must be observed to ensure
pressability
Conduct the wax cut-back and check with a silicone key.
19
3. Contouring for the layering technique
Contouring of the “dentin core” and/or ceramic shoulder depends on the available space.
The following points have to be observed:
– Precisely attach the restoration margins and/or shoulder with wax.
– In bridges, contour the basal surface of the bridge pontic.
– Contour the dentin core.
– Observe a wax thickness of at least 0.7 mm to avoid incomplete press results.
intered IPS e.max ZirCAD framework onto which IPS e.max Ceram ZirLiner has been fired on the model.
S
Precisely attach the restoration margins and contour the “dentin area”. In bridges, contour the basal surface of the bridge pontic. Observe the minimum layer thickness of 0.7 mm.
20
Sprueing
Always attach the sprues in the direction of flow of the ceramic and at the thickest part of the wax-up so that smooth
flowing of the viscous ceramic during pressing is enabled. Depending on the number and size of objects to be invested,
either the 100 g, 200 g, or 300 g IPS Investment Ring System is selected. Bridges must only be pressed in the 200 g or
300 g IPS Investment Ring System. Before sprueing, weigh the ring base and record the weight (seal the opening of the
ring base with wax).
We recommend the following procedure to determine the
accurate wax weight:
– Weigh the IPS ring base (seal the opening of the ring base
with wax)
– Position the objects to be pressed on the ring base and
attach them with wax. Weigh again.
– The wax weight is calculated by deducting the weight of
the ring base and the weight of the ZirCAD framework
from the total weight.
– Use the respective number of ingots for the calculated wax
weight.
1 ingot 2 ingots 3 ingots 6 ingots
Wax Weight max. 0.7 g max. 1.7 g max. 2.2 g max. 5.1 g
Investment Ring System 100 g, 200 g 100 g, 200 g 300 g 300 g
Clinical Steps, Framework Preparation, Contouring, Pressing Procedure
The following sprueing guidelines must be observed:
– Observe a distance of at least 10 mm between the wax-up objects and silicone ring.
– The maximum length (wax objects + sprue) of 16 mm (100 g, 200 g) or 20 mm (300 g) must not be exceeded.
– If only one object is invested, a second short (blind) sprue must be placed. This ensures that the switch-off function of
the furnace works properly at the end of the pressing procdure.
– If the 100 g IPS Investment Ring System is used, a somewhat steeper sprueing angle to the ring base must be observed.
– In bridges, provide at least one sprue for each bridge element.
– In large crowns and/or bridge units (e.g. molars) 2 sprues should be provided (see”Sprueing of long-span bridges”).
21
Sprueing the single tooth restorations
min.
10 mm
45-60°
3
-
8
m
m
max. 16 mm
min. 10 mm
min.
10 mm
45-60°
3
-
8
m
m
max. 16 mm
min. 10 mm
min.
10 mm
45-60°
max. 16 mm
m
in. 10 mm
3
-
8
m
m
max. 20 mm
min. 10 mm
3-
8
m
m
min.
10 mm
PS Investment Ring System 100 g, 200 g or 300 g
I
Sprueing of bridges
IPS Investment Ring System 200 g or 300 g
Anterior Crown
3-Unit Bridge
PS Investment Ring System 100 g, 200 g or 300 g
I
Posterior Crown
Long-Span Bridges
IPS Investment Ring System 300 g
22
The following sprueing guidelines must be observed:
Investment Ring System
Diameter of the wax wire
Length of the wax wire
Length of the wax wire including
waxed-up object
Sprue attachmenet point at the
waxed-up object
Sprue angle to the waxed-up
object
Sprue angle to the ring base
Design of the attachment points
Distance between the objects and
the sprues
Single-Tooth Restorations
100 g, 200 g, 300 g
3 mm
min. 3 mm, max. 8 mm
max. 16 mm (100 g, 200 g)
max. 20 mm (300 g)
thickest part of the wax-up
axial
45–60°
round and slightly tapered,
no sharp angles or edges
min. 3 mm
Bridges
200 g, 300 g
3 mm
min. 3 mm, max. 8 mm
max. 16 mm (200 g,)
max. 20 mm (300 g)
bridge abutments and
each bridge pontic
axial
45–60°
round and slightly tapered,
no sharp angles or edges
min. 3 mm
Clinical Steps, Framework Preparation, Contouring, Pressing Procedure
Distance to the silicone ring
Note
On the selected IPS investment ring base, attach sprues in the direction of flow of the ceramic and to the thickest parts of the restorations.
(check with the IPS Sprue Guide)
Correct sprueing is checked using the IPS Sprue Guide.
min. 10 mm
Larger bridges may also be placed in
Tip
To faciliate divesting, the position of the objects can be marked on the ring base with a
little wax prior to investment.
min. 10 mm
(check with the IPS Sprue Guide)
the center of the investment ring.
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