Comparative Evaluation of Marginal Fit of Castings Using Conventional and Accelerated Casting Technique with Different Pattern Materials: An In Vitro Study

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ORIGINAL RESEARCH
no significant difference in marginal gap of crowns fabricated by
conventional and accelerated casting technique.7
Some studies have reported that this procedure is technique
sensitive. According to Konstantoulakis etal., by using an accelerated
casting process, fac tors like variations between batches of the same
investment, mixing and handling of investment, the temperature
of the prepared oven, and type of wax may affect the stability of
investment mold, which may result in a marginal discrepancy.2
Alex etal. stated that quality of preparation (undercuts and taper
of preparation), impression, working cast, quality of the wax used,
In t r o d u c t I o n
The close adaptation at the margin of cast restoration is one
of several important aspects that affect the success of fixed
restorations.1 Effective tooth preparation, exact impressions,
precision castings with meticulous finishing, and cementation
techniques are essentially required for castings to fit marginally.
Dr William H Taggart’s lost wax process is used to cast metal
crowns. Before casting is done, a one- or two-stage wax removal
operation is used.2 It takes about 3–4 hours to complete this
process. Constant efforts have been made to speed up this
time-consuming procedure. There is currently a need for a
casting method other than the traditional one.3,4 The majority
of these activities focus on “conventional” casting and investing
methods.5 A cast restoration’s accuracy of fit is crucial for both
clinical success and lifespan because it reduces plaque build-up
in the marginal area, offers better mechanical characteristics,
exposes less cement to the oral environment, and produces a
better esthetic outcome.6 Numerous papers describe efforts to
optimize the casting oper ation in dentistry by enhancing materials
and techniques. The general acceptability of a cast restoration is
influenced by a varie ty of elements, and it can be improved using
a variety of ways.
Accelerated casting technique allows complete crowns to be
invested and casted in 30 minutes and gives comparable results
to conventional technique. S Parithimarkalaignan et al. concluded
1–6Department of Prosthodontics and Crown & Bridge, Teerthanker
Mahaveer Dental College and Research Centre, Teerthanker Mahaveer
University, Moradabad, Uttar Pradesh, India
Corresponding Author: Sujeet Patil, Department of Prosthodontics and
Crown & Bridge, Teerthanker Mahaveer Dental College and Research
Centre, Teerthanker Mahaveer University, Moradabad, Uttar Pradesh,
India, Phone: +91 7709917887, e-mail: sujeet.patil77@gmail.com
How to cite this article: Patil S, Gopi A, Kumar S, etal. Comparative
Evaluation of Marginal Fit of Castings Using Conventional and
Accelerated Casting Technique with Different Pattern Materials: An In
Vitro Study. World J Dent 2023;14(8):700–704.
Source of support: Nil
Conflict of interest: None
Comparative Evaluation of Marginal Fit of Castings Using
Conventional and Accelerated Casting Technique with
Different Pattern Materials: An In Vitro Study
Sujeet Patil1, Akash Gopi2, Shalabh Kumar3, Abhishek Gupta4, Gyan Abhishek5, Chandan Kumar6
Received on: 06 July 2023; Accepted on: 07 August 2023; Published on: 20 September 2023
Ab s t r A c t
Aim: The aim of the study was to evaluate and compare the marginal fit of casting made by conventional and accelerated casting techniques
using inlay wax and pattern resin.
Materials and methods: A total of 40 cobalt-chromium copings were fabricated on typodont tooth using two types of pattern materials and
two different casting techniques and divided into two groups of pattern resin and inlay wax with 20 copings each and two subgroups of
conventional and accelerated casting technique with 10 copings each. A marginal gap of copings was examined under a stereomicroscope,
and collected data were statistically analyzed.
Result: Mean gap in inlay wax castings made using the traditional casting process was 258 µm, whereas the marginal gap in inlay wax castings
made using the accelerated casting technique was 300.3 µm. The castings created with autopolymerizing pattern resin using conventional and
accelerated casting procedures had maximum mean gaps of 358.4 and 392.5 µm, respectively.
Conclusion: Within the constraints of this investigation, all castings fall within a range of clinical acceptability. Inlay wax is a better material
than autopolymerizing pattern resin for pattern fabrication, and the conventional casting technique has the least vertical marginal discrepancy
when compared to the accelerated casting technique.
Clinical significance: Traditional casting methods that adhere to manufacturer instructions take a lot of time. Although documented, the
accuracy of accelerated casting procedures using base metal alloys has not been sufficiently investigated. Also, there are very few studies to
compare two pattern materials; inlay wax and pattern resin.
Keywords: Accelerated casting, Casting, Inlay wax, Marginal discrepancy, Pattern resin.
World Journal of Dentistry (2023): 10.5005/jp-journals-10015-2258

Marginal Fit of Castings Using Conventional and Accelerated Casting Techniques
World Journal of Dentistry, Volume 14 Issue 8 (August 2023) 701
index, a tiny layer of petroleum jelly was placed to help separate
the wax pattern. Type 2 inlay wax (MDM corporation, Delhi, India)
was melted, put to the prepared index, and then fitted over the
prepared tooth. The wax pattern was removed after the inlay
wax had hardened. If any void or inaccuracy was found in the
pattern, it was discarded. A total of 20 wax patterns were made
(group II), out of which 10 were cast using the conventional
casting technique (subgroup IIA) and 10 using the accelerated
casting technique (subgroup IIB).
Attachment of Sprue Former
All patterns had a reser voir that held performed sprue. T he pattern
was spread after seating on the tooth to reduce deformation.
Sprue’s opposite end was connec ted to the crucible and was joined
to the pattern at a 45° angle. To reduce porosity and increase mould
filling, the point of at tachment was flared rather than restri cted. All
patterns were immediately invested.
Investing
To prevent distortion, all patterns were promptly invested using
phosphate-bonded investment material (Bego, United States
of America). The casting ring liner was used to line the ceramic
casting ring. The prepared pattern’s edge and top of the ring were
separated by 6 mm. For traditional casting, phosphate-bonded
investment material was used. According to the manufacturer’s
guidelines, investment was mixed. After mixing, a paintbrush was
used to coat the entire pattern with a thin layer of investment.
Bench set time for a traditional casting method was between
1 and 1.5 hours, while for the accelerated casting technique, it was
15 minutes.
Wax Pattern Elimination
For conventional casting—the casting ring with investment was
placed in a burnt-out furnace. It was continually heated at a rate of
8°C per minute from room temperature to 950°C.
For accelerated casting—to ach ieve complete burnout, the set
investment mold was put directly into a burnout furnace that was
preheated and kept at 950°C for 30 minutes.
Casting
An induction casting machine was used. The investment mould
was removed from the furnace and p laced in the preheated casting
crucible. Crucible was released, and nickel-chromium alloy was
sufficiently heated to reach molten condition; centrifugal force
ensured that the casting process was complete.
Divesting of the Cast Coping
After casting, the hot casting ring was bench-cooled until it
reached room temperature. Casting was lifted free when the
investment was split along its long axis. An incredibly thin
abrasive disc was used to remove the sprue. All the castings
were polished (Fig. 1). If, after retrieval of casting, there was any
casting defect, the casting was discarded, and a new casting was
prepared. The marginal fit of the crown was then assessed using
a stereomicroscope after it had been sandblasted and placed on
the prepared tooth (Fig. 2).
Statistical Analysis
Statistical analysis was performed by IBM Statistical Package for
the Social Sciences (SPSS) (IBM Corp. Released 2011. IBM SPSS
Statistics for Windows, Version 20.0. Armonk, New York, United
and accuracy of castings all have an impact on how accurately a
casting fits.6
Only if the castings produced by the accelerated casting
technology meet crucial clinical requirements can they be
recommended for regular usage.7 One of the key components
of long-term clinical effectiveness is the restoration’s marginal
integrity. The main goal of a cast metal restoration is to achieve
a flawless fit, and when that goal is not achieved, a thin line of
cementing is exposed to the action of saliva and other oral fluids,
which causes marginal leakage and the start of secondary caries.8
Wax or acrylic resin is typically used for the formation of
patterns in casting pro cedures involving the burnout of a pattern.9
Castings requiring better dimensional stability have been made
using autopolymerized acrylic resins. The time available for
manipulation is decreased by autop olymerization, but the stif fness
and hardness of the autopolymerized resin enable abrasive tools
to be used for contouring. Acrylic resin’s primary drawback is its
significant polymerization shrinkage.
In the literature, there is a lack of data which compares the
traditional casting method and accelerates casting with pattern
resin and inlay wax for their accuracy after the casting procedure.
Although documented, the accuracy of accelerated casting
procedures using base metal alloys has not been sufficiently
investigated. The aim of the current study was to evaluate and
compare the marginal fit of casting made by conventional and
accelerated casting techniques using inlay wax and pattern resin.
MAt e r I A l s A n d M e t h o d s
This original research was carried out in the Department of
Prosthodontics and Crown & Bridge, Teerthanker Mahaveer Dental
College and Research Centre, Morad abad, from July to December 2022.
Preparation of Index
To fabricate patterns of uniform size, an inde x was prepared from hard
putty material (additio n silicone) on an unprepared t ypodont tooth.
Tooth Preparation
After preparing the in dex, tooth preparation was done for all met al
crowns (nickel–chromium alloy) with supra gingival finish line.
Resin Pattern Fabrication (Group I)
Petroleum jelly was applied to the prepared tooth so that
the resin pattern was easily separated. Powder and liquid (GC
Corporation Tokyo, Japan) were dispensed in a mixing jar as per
the manufacturer’s instructions. The mixture was then transferred
to the prepared put ty index. The putt y index, along with resin, was
adapted to the prepared tooth. T he resin was allowed to be set, and
the index was removed. The resin pattern was separated from the
prepared tooth without distortion. If any void or inaccuracy was
found in the pattern, it was discarded. A total of 20 resin patterns
were made (group I), out of which 10 were cast using conventional
casting technique (subgroup IA) and 10 using accelerated casting
technique (subgroup IB).
Wax Pattern Fabrication (Group II)
On the prepared tooth, a thin layer of die separator (Interdent
d.o.o, Slovenia) was applied. The film moistened the tooth
surface, enabling wax to come into closer contact with the
surface and improving pat tern accuracy. Additionally, it made it
simple to remove wax patterns from teeth. On the inside of the

Marginal Fit of Castings Using Conventional and Accelerated Casting Techniques
World Journal of Dentistry, Volume 14 Issue 8 (August 2023)
702
that the variables were statistically significant. Castings fabricated
using inlay wax and conventional casting technique had better
marginal fit compared to castings prepared using accelerated
casting technique.
dI s c u s s I o n
Complex steps are involved in the production of cast restoration,
which could have an impact on the castings’ dimensions and fit
precision. The dimensional accuracy depends on a number of
variables, including the fabrication process and the materials used
to make the prosthesis.10
In this current study, an attempt was made to compare both
the techniques and pattern materials simultaneously. There is a
scarcity of literature whi ch compare both the techniques as we ll as
the materials. The method us ed in the present study for fabricating
patterns was less time-consuming and can be used effectively in
clinical conditions. Stereomicroscope was used to evaluate the
marginal discrepancy, which was more accurate compared to other
techniques like the use of an explorer or making impressions.
In 1988, Marzouk and Kerby made the first known attempt to
accelerate the lost wax procedure for a complete cast crown.11
Campagni and Majchrovicz also used an accelerated casting
procedure and evaluated the fit of dowels and cores produced
from noble alloy.12 In the present study, the marginal f it of castings
made by conventional procedure was found to be superior
as compared to castings made by accelerated procedure. Our
results were comparable to a previous study done by Bailey and
Sherrad, who came to the same conclusion that castings made
with conventional casting procedure were b etter fit as compared
to the castings made with accelerated casting procedure using
phosphate-bonded investment material.13 Lesser marginal
disparity with traditional casting compared to the accelerated
casting process was mostly caused by longer burnout cycles.
According to Schilling etal., accelerated procedures may benefit
from the typical exothermal setting reaction of phosphate-
States of America: IBM Corp.). The obtained data were statistically
analyzed by applying an independent t-test for intergroup as
well as intragroup comparison. In the present study, p < 0.05 was
considered as the level of significance.
re s u lt s
Tab le  1 shows an intergroup comparison of the marginal fit of
castings using inlay wax and autopolymerizing pattern resin.
The inlay wax showed a mean value of 279.15 ± 25.87, while
pattern resin showed a mean value of 375.45 ± 35.40. A p-value
obtained was 0.0001, concluding that there was a statistically
significant difference between the two variables. Hence, castings
from inlay wax had a better marginal fit compared to those of
autopolymerizing pattern resin.
Tab le  2 shows an intergroup comparison of the marginal
fit of castings of autopolymerizing pattern resin by accelerated
technique and conventional technique. Th e mean marginal gap for
the accelerated casting technique was 392.50 ± 38.4 0, while that for
the conventional technique was 358.40 ± 22.91. The two variables
were statistically signif icant (p = 0.0001). Castings fabricated using
auto polymerizing p attern resin and conventional casting technique
had better marginal fit compared to castings prepared using an
accelerated casting technique.
Tab le3 shows an intergroup comparison of the marginal fit of
castings of inlay wax by accelerated technique and conventional
technique. The accelerated technique showed a mean marginal
gap of 300.30 ± 11.17, and the conventional technique showed
a mean marginal gap of 258 ± 17.16. A p-value of 0.0001 showed
Fig. 1: Crown seated on tooth Fig. 2: Evaluation of marginal gap
Table 1: Comparison of marginal fit of castings of inlay wax and
autopolymerizing pattern resin
Group N Mean Standard deviation p-value
Inlay 20 279.1500 25.87678 0.0001
Pattern 20 375.4500 35.40514
Table 2: Comparison of marginal fit of castings of autopolymerizing
pattern resin by accelerated technique and conventional technique
Group N Mean Standard deviation p-value
Accelerated 10 392.5000 38.40790 0.027
Conventional 10 358.4000 22.91627
Table 3: Comparison of marginal fit of castings of inlay wax by
accelerated technique and conventional technique
Group N Mean Standard deviation p-value
Accelerated 10 300.3000 11.17587 0.001
Conventional 10 258.0000 17.16586

Marginal Fit of Castings Using Conventional and Accelerated Casting Techniques
World Journal of Dentistry, Volume 14 Issue 8 (August 2023) 703
below the crown margins. Dental restorations must have a precise
marginal seal in order to meet biological, physical, and esthetic
requirements; otherwise, the restorations risk failing.
This study has a few shortcomings. Clinical events cannot
be precisely replicated in laboratory research. Also, the marginal
disparity was measured in this study without the cast copings
being permanently ceme nted, which might have an impact on the
marginal adaption. Studies by Hung etal., and Quintas etal., claim
that following cementation, marginal accuracy greatly rises.21,22 In
this investigation, castings are only examined with a single uni t wax
pattern. More resea rch is needed to determine how well the stated
rapid casting procedure performs when more than one unit wax
design or fixed par tial denture or cast partial denture framewor k is
invested in the same ring. Other investment materials could have
been utilized instead of the phosphate-bonded investment that
was used in this investigation.
The outcomes of the exp edited technique stimulate additional
investigation to pinpoint the elements that improve the marginal
fit of cast restorations. Additionally, more studies are required to
improve the use of pattern materials, such as light cure pattern
materials or the use of computer-aided design/computer-aided
manufacturing to guarantee pattern consistency, as well as newer
techniques, such as direct metal laser sintering.
co n c lu s I o n
Within the limitations of the present study, it can be concluded
that patterns fabricated using inlay wax had a better marginal fit
compared to those of autopolymerizing pattern resin. Castings
prepared using the conventional casting technique had a better
marginal fit compared to those using the accelerated technique.
All cast copings obtained by var ious groups fell within the clinically
acceptable range for the mean vertical marginal discrepancy.
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that had been patched and pooled during creation.16
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create copings that demand higher dimensiona l stability. The time
available for manipulation is de creased by autopolymerization, but
the stiffness and hardness of the autopolymerized resin enable
abrasive tools to be used for contourin g. The primary drawbacks of
acrylic resin are its hi gh polymerization shrinkage and resi due after
burnout (show shrinkage within 24 hours of production).
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resin has higher rigidity and hardness, allowing for the sculpting
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castings created with inlay wax as the p attern material had a smaller
margin of error than castings made with au topolymerizing pattern
resin. Other pattern materials which can be used include the use
of light cure pattern resin, which has advantages like faster and
more complete curing, reduced p orosity as mixing is generally not
required, almost instant finishing, and adequate working time for
complex procedures. T he intensity of incident light, exposure time,
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clinical success of the cast restoration in the oral cavity depend on
the casting’s correctness of f it.20 Clinically, poor margins serve as a
niche for dental plaque. Mo reover, it may result in secondary c avities

Marginal Fit of Castings Using Conventional and Accelerated Casting Techniques
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