Model Cast Dentures

Model cast dentures a reliable solution for removable prostheses made from durable chromium-cobalt-molybdenum alloy. 

Model cast dentures offer a reliable and efficient solution for removable prostheses, with the base made from durable chromium-cobalt-molybdenum alloy. 

Advances in digital technology enable quick production of these dentures at an economical price point; eliminating manual modeling processes typically associated with waxing. With 3D measured models directly accessible through CAD systems to be used during design stages, modernisation has revolutionised provision of model cast partial denture fittings.

Classical casting process

  • Duplication of the model 
  • Modeling with modeling wax
  • Creation of the casting channels and attachment of the prefabricated casting funnel
  • Embedding of the wax model in investment suitable for casting to create the casting sleeve
  • Preparation of the model casting sleeve for the casting sleeve and casting of the CoCr prosthesis
  • Removal of the prosthesis from the casting sleeve and removal of the casting channels
  • Sandblasting and manual finishing of the model casting prosthesis with polishing-milling tools
  • Fitting of the prosthesis to the model by removal of interfering areas
  • Final polishing of the prosthesis


Digital procedure

  • 3D measurement of the model with a dental 3D scanner
  • Construction of the prosthesis in the dental CAM software
  • Transfer of the 3D data of the prosthesis to the metal printer
  • Removal from the printer and stress relief annealing in the furnace for about 2h.
  • Removal of the support structures and sandblasting of the prosthesis
  • Fitting of the prosthesis to the model by removal of interfering areas
  • Automatic electropolishing


Here, the digital process offers considerable advantages over the classic process when creating cast model dentures. 


Time savings

2oneLab’s powerful digital workflow revolutionizes the traditional modeling process of prostheses. By rapidly scanning and digitally designing in just a few minutes, time is greatly reduced compared to manual methods. Their 2CREATE 3D metal printers are able to output up to 5 model cast prostheses within only 2-3 hours; further decreasing production times even more through stress annealing prior fitting that takes another two hours per iteration. The accuracy delivered by this technology allows for minimal rework during fitting while electro-polishing processes require no human intervention and can provide 12 model cast dentures with remarkable speed – taking around 1 hour depending on system selection!

A skilled dental technician can thus easily produce up to 15 model cast prostheses per day in a single-shift operation.


Cost savings

Cost efficiency can be significantly improved in the production of cast model dentures. By utilizing 3D printing, personnel costs are low due to high time savings and reduction of manual work steps. Additionally, material cost savings are also notable as only necessary amounts for manufacturing need to be used; wasted metal powder can even be reused after adequate filtration processes have been applied.

3D printing presents a unique opportunity to substantially reduce the cost of producing cast model dentures. By cutting down on manual work steps, personnel costs are drastically decreased while raw materials wasted during production can be filtered and reused for future projects. This method offers an environmentally conscious solution that will result in tangible savings over time.



Digital prosthetics manufactured with 3D printing technology are more straightforward to master than the traditional practice of manual model casting. In addition, prefabricated design templates known as DMEs enable automatic construction of such items without much effort and minimal learning curves for dental professionals. Learning how 3D printing works usually doesn’t take more than one or two days for any dental professional.


Work safety

Health-wise, this method’s elimination of dangerous fumes and temperatures makes it much safer in comparison with manual processes; furthermore its use ensures significant reduction (upwards of 80%) in CoCr fine dust which can be hazardous if inhaled by technicians operating machinery over long periods of time.