CA1265363A - Method to produce artificiel dentures - Google Patents

Abstract

ABSTRACT
This invention pertains to a method to fabricate economical dentures for edentulous dental patients comprising attaching full arch unitary upper and lower sets of artificial teeth to denture base material and fabricated by a process developed for the purpose of utilizing these sets of teeth and converting them into finished upper and lower dentures by the use of a specialized apparatus comprising part of the invention. The process eliminates the conventional procedure of mounting individual artificial teeth in the normal process of fabricating dentures. Dentures are also disclosed formed from individual teeth but employing a novel tacking procedure to facilitate alignment and orientation of the teeth.

Description

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BACXGROUND OF_E_NVEIITION
The production of artificial dentllres is an art which has existed for at least several hundred years and over that period has constantly been improved to achieve ~he ultimate goal of maximum comfort to persons wearing such dentures and close simulation to natural dentitions. One of the principal diffieulties involved in the preparation of artificial dentures comprises the arranging of artificial teeth and connecting the same to denture base material to produce finished dentures.
The majority of dentures made at the present time include the connection of sets of individual artificial teeth to the : denture base material and this is accomplished, in the main,~by dental laboratories, but is by no means r~stricted to the same in that some dentists prefer to fabricate the dentures for their patie~ts.
In general, the preparation of full dentures commences with taking impressions of both upper and lower edentulous arches, and establishing their relative posi ion to one another both at rest and in function. These methods are ~ ~o desc~rlbed in texts and other publi~ations, and result ~enerally : in the preparation of a "bite~reeord" used by the dental : laboratoxy from which a try-in is fashionedO
: ~ The:impressions are taken by procedures we~l known to ;. the art using alginate impressivn material or the:like, and : 25 models of the patient's jaws and gums, known as ~asks areformed ~rom se able materlals such as certain gypsum material, commonly referred to as "dental stone". A basepla~e is.next formed upon the cast using a thermoplas~ic material in sheet form, by ~oftening and adapting it over the cast. Upper and lower baseplates prepared in this manner ar2 then used by the ~.

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den~ist ~o estabIish a bite record. ~he ~aseplates are introduced into the mouth of the patient, separated by soft wax which is deformed by the action of the patient's jaws as they axe guided into their proper position by the dentist. The soft wax is modeled in a relatively rough labial contour of the teeth as they will be positioned in the finished denture, and the relationship between the jaws is transferred to a dental articulator which serves to hold the casts in the same relative posit1On, as described in greater detail hereinafter. Also, : 1Q ~ertain measurements made with appropriate lnstruments ::
determine the preferred vertical relation between the central, :
; ~ forward portion~:of a patient's gums on the respective~jaws,' : : ~ known professionally as the ~i~cisive papilla".
:~ Individual posterior and anterior ar~ificial teeth then are imbedded in wax material, known as "set-up wax", : applied to the baseplates to conform to surfaces determined by : ~ the:"bite rec~rdn. ~hsn additional wax is applied bet~een the gingi~al surfaces of the artificial teeth and the baseplates in a manner to resemb:le natural gum~contours.~ The forégoin~
20 ~ operations:are:per~ormed while the casts are mounted in the : upper and lcwer~bows~or members:of~an articulator~which permits re1ative movement~between~the upper and lower sets o~
artlfic1al teeth~formed on the~ ca~ts-by the foregoinq . procedures and there~y enablPs a dental technician or dentist to provide desirable occlusion and ~unction be~ween the artificial teeth on the respective cast5. Mounting such teeth on the cast or model by ~he foregoing procedl1re requires extensive skill and is relatively time-consuming. The elimination:of such substantial consumption of time is an essentia} objective of the present invention.
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~2~;3~3 After the above procedures have been completed, the baseplates and the contoured wax material and artificial teeth mounted thereon then are removed from the casts respectively and may be tried in the mouth of the patient if desired. With the upper and lower casts attached thereto, they are then invested in suitable molding compounds, generally of a gypsum nature. The baseplate and set-up wax are removed from the hardened investment by heating and softening methods to provide a cavity into which permanent denture base material is injected or moldea for connection to the ridgelap and gingival surfaces of the artificial teeth by the well-known "lost wax" process.
The foregoing procedure is generally exemplary of the methods used at present to fabricate artificial dentures.
Various modified steps of the procedure occur at present, but in general, it will be seen that one of the principal diiculties arising from the procedure comprises the mounting of individuaL artificial teeth upon the wax substrate to which they are attached and also to provide proper occlusion between the opposed masticating surfaces of the teeth in the upper and lower dentures.
This patent may be considered in view of U.S.P.
4,551,098 teaching the use of full arch upper and lower sets o~
artificial teeth which are integrally connected together in said sets and opposite sides of each arch formation are braced to stabilize the shape. The teeth provided in said full arch sets have certain characteristics which resemble natural teeth, while at the same time, facilitati~g the molding of such teeth in molds which preferably are relatively simply~. In this regard, it is to be noted that the use of full arch sets of artificial teeth to form dentures is not new from a basic 3~3 standpoint. Previous attempts to simplify the formation of artificial dentures have included the use of such full arch sets of artificial teeth and typical examples of the same are found in such prior U.S. Patents as No. 1,814,717 to Maizner, dated July 14, 1931; No. 2,539,882 to Zilinsk:i, dated January 30, 1951; No. 2,768,440 to Elliott, dated October 30, 1956; and No. 4,099,329 to Hawthorne, dated July 11, 1978.
In addition to the use of full arch sets of artificial teeth in the making of dentures as noted above, various procedures for the forming of dentures with the aid of articulators in order to attempt to minimize the amount of time consumed have been the subject matter of other prior U.S.
Patents, including No. 1,814,717 to Maizner, dated July 14, 1931; No. 2,171,759 to Meyer, dated September 5, 1939; and No. 4,189,837 to Stele, dated February 26, 1980, as well as prior British Patent No. 295,768 to Perks, dated August 23, 1928 and prior German Patent No. 508,921 to Kantorowicz, dated October 2, 1930.
Further to facilitate the formation of artificial teeth with an enamel simulating layer, prior U.S. Patent ~o. 1,547,643 to Clapp, dated July 28, 1925, illustrates a form of mold and technique to accomplish this, while prior U.S.
Patent No. 1,907,923 to Willis, dated Nay 9, 1933, is one example of a measuring device used incidental to determining desirable bite level between artificial dentures and thereby acilitate the comfort of using the same.
In accordance with one aspect, the invention is a method of forming a denture having a plurality of ar~ificial teeth comprising the steps of:
(a) using negative impressions of at least a portion i~ ;

3~:i;3 of a jaw of a patient having at least one edentulous portion to make therefrom a model of said jaw portion, (b) applying to the model actinic light curable, moldable, denture base material to conform the same to the edentulous portion of th~ model, (c) exposing the denture base material to actinic light for a time sufficient to harden said material to form a denture base, (d) movably affixing a plurality of artificial teeth to the denture base by applying to the denture base or to the teeth or both an additional quantity oF actinic light curable, moldable, denture base material and contacting said denture base with said teeth;
(e) irreversibly affixing the teeth to the denture base by exposing minor proportions of the added actinic light curable material to actinic light for a time sufficient to cure said minor portions, said irreversible affixation being insufficient to cure a major proportion of the added material, and (f) substantially fully hardening said material by irradiating it with actinic lig~t.
In accordance with a second aspect, the invention is ~ .
a method of forming a denture having a plurality of axtificial teeth comprising the steps of:
(a) forming a denture base;
(b) movably affixing at least one tooth but less than all of:said pluralIty of teeth to a denture base by applying to said denture base or said at least one tooth or both, a quantity of actinic light curable, moldable denture material and joining said at least one tooth to said denture 5i3~3 base with said denture material;
(c) finely adjusting said at last one tooth by moving said at last one tooth and said denture material joining it to said denture base, (d) exposing at least a portion of said actinic light curable, moldable, denture material to actinic light sufficient to irreversibly affix said finely adjusted at least one tooth, (e) movably affixing at least one other tooth to said denture base by applying to said denture base or said other tooth or both a quantity of actinic light curable, moldable, denture material and joining said other tooth to said denture base with said denture material;
(f) finely adjusting said other tooth by moving said other too-th and said denture material joining it to said denture base; and (g) as a step separate from step ~d), exposing at least a portion of said actinic light curable, moldable, denture material to actinic light sufficient to irreversibly affix ~aid finely adjusted other tooth.
: BRIEY DESCRIPTIO~ OF THE DRAWINGS :-:
For the purpose of illustration, but not of limitation, e~bodiments of the invention will be hereinafter described, in which Figure 1 is a top plan view of an exemplary full arch unitary set of upper artificial teeth, embodying the principles of the present invention.
Figure 2 i6 a sectional view taken on the line 2-2 of Figure 1 and showing the cross-~ection o~ a central tooth of the set of full arch teeth, shown in Figure 1, the labial face 3~3 ~ 4053-133 of the tooth sloping in at the gingival and out at the incisal, to facilitate remo~ing the teeth from a mold.
Figure 2a is a view corresponding to Figure 2, but showing the cross-sectional shape of a normal central artificial tooth in which the labial face of the tooth is in at the incisal, which would impair the removal of the tooth from the type of mold preferred to manufacture the teeth of the present invention.
Figure 3 is a vertical sectional view of a canine tooth of the set shown in Figure 1, as seen on the line 3-3 thereof, and illustrating as in regard to Figure 2, the manner in which the canine tooth slopes inwardly ak the gingival and outwardly at the incisal to facilitate the removal of the same from the mold.
Figure 3a is a view simi}ar to Figure 3 but shows a DectiOnD~ view of a more or le~s conventionDl canine artificiD

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tooth in which the labial surface extends inwardly at the incisal, as well as at the gingival.
Fig. 4 is a sectional view of a posterior tooth formed in accordance with the invention, as seen on the line 4-4 o Fig. 1, and illustrating labial surfaoes which slope inwardly from the gingival toward the occlusal.
Fig, 4a illustrates a similar cross-sectional shape of a conventional posterior artificial tooth in which the labial surface t.hereo~ i~ substantially perpendicular to the occlusal plane illustrated by the bottom horizontal phantom line.
Fig. S is a plan view of the occlusal surface of t~e eY.emplary full arch set of artificial teeth ~hown in P~
Fig. 6 is a front elevation of the full arch set of artificial upper teeth shown in ~ig. 1.
~ g. 7 is a side elevation of an exemplary full arch set of upper and lower artificial teeth, including employed in deta-ls the present invention and shown in occlusion with respect to each other, ~aid view showing ln particular the 20~ sloping labial surfaces of the central teeth o the respectiYe sets thereo~, which correspond generally to Fig. 2.
Fig. 8 is a ~ront elevation of an exemplary full arch ~et of ~ower artificial teeth and illustrati~g as in Fig. 6 the indented interproximal sarfaces adjacent the gingival ends of the ~eeth.
Fig. 9 is a vertical sectional view of an exemplary set of upper snd lower dies in which full arch sets o~ upper and lower artificial teeth are capable of being molded to have the general characteristics especially shown in Figs. 6-8.
Fig. 10 is a top plan view of an articulator of a B~ ~
.";~ --simplified type embodying the principles of the present invention.
Fig. 11 is a side elevation of the articulator shown in Fig. lO, as viewed from the right-hand side thereof, shown in said figure, Fig. 11 also including fragmentarily in phantom, an elevated position of the upper bow of ~he articulator.
Pig. 12 is a fragmentary vertically sec~ioned detail of the pivotal support for the upper bow, as seen on the line 12-12 of Fig. 10.
Yig. 13 is another horizontal sectional view, showing a detail of said pivotal means for the upper bow, as seen on : the line 13-13 of Fig. ll.
Fig. 14 is a fragmentary vertical sectional vi w showing details for the support means o~ the mo~nting table, shown on the line 14-14 of Fig. ll.
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Fig. 15 is a fragmentary horizontal sectional view of the support means shown in 14, but as seen on the line 15-lS of Fig. ll.
;~ ~ 20 Figs. 16, 17, and lB~respectively show top, side, and : bo~tom views o~: the support table shown in Fig. 11.
: : Fig. l9 is a side èlevation o a measuring instrument useful in conjunction with the present invention, as shown in :
~ the ragmentary portion of:a human mouth,~illustrated in :
phantom.
Fig. 20 is a front elevation of the instrument shown : in Fig. 19.
Fig. 21 is a transverse sectional view of the instrument shown in Fig. 20, as seen on the line 21-21 thereof.
~ig. 22 is a composite side elevational view of a ~- .

pair of stepped wedge-like support members used in conjunotion with levelling an upper cast with respect to the support table and being disposed between said table and he forward portion of the upper cast selectively in spacings of one millimeter.
S Pig. 23 is a ~op plan view of one of the wedge-like members shown in Fig. 22.
Fig. 24 and 25 respectively are respective vlews of different types of alternate support means used in ~rticulators not illustrated in the foregoing views, in lieu o~ the supporting table ac~ually shown in said views.
Fig. 26 is a side elevation of an exemplary upper gum or jaw of a patient and comprises a dental cast thereof.
: ~ ~ig. 27 is a perspe~ i~e view:of an exemplary lower : cast simula~ing ~he lower jaw:of a pat1ent.
:~ 15 Fig. 28 is~a ~side view of the upper and:lower casts~
: of Flgs~. 26 and 27, being joined in operative relationship by means of a ~aw-relat~on hite record, the elements shown : respectively in Figs. 26-28 normally~heing supplied by a~
~'~: : dentist for purposes o~ utilizing the present invention.
20~ Fig.~Z9 is~a view similar to ~ig. l9:and~showing~ t~he~
instrument of~Figs. 19~and;20 x~espectively ~en~aging the lower : end~of the upper:lip and the forward por~ion of the upper jaw or gum of a~patient~:to:provide~a required measurement incident to the:use o~the~wedge member shown~in Figs. 22 and~23.
25 ~ Figs. ~0-4~1 successively~illustrat2:various ~StQpS of the ~ethod comprising one of the~essential features of the present invention, said steps being descri~bed iil detail ~: hereinafter in the speciflcation~ `
Fig. 42 is a perspective vlew~of an exemplary set of artificial upper and lower dentures in which fu.Ll arch se~s of ,, ~2~3~3 the teeth of the present invention are included.
Figure 43 depicts tackin~ of teeth to form a partial denture.
DETAILED DESCRIP'rION OF TlIE PREFF.RR~D EMBOI)IMENT
The present invention includes a number of related facets all leading to the common goal of producing satisfactory, reasonably life-like artificial dentures which include full arch unitary upper and lower sets of artificial teeth, thereby resulting primarily in a 1~ substantial saving i~ time to produce the so-called dental ~set-ups" which, as such, are then processed by conventional methods into finished dentures. In the foregoing~ reference has been made to the great skill and amount of time required to place individual artificial teeth on baseplates and wax set-ups to which aesthetic wax `
configurations resembling natural gums are included in the "set-ups", and it is in this area of the productlon of artificial dentures that the present invention provides very substantial advantages.
As is~evident from the prior art referred to - ~ hereinabove, the use of full arch sets of artificial teeth~
s not new per se. Attempts have been made by others~to~
commercializ~ full arch sets of molded artificial teethj~
but for~ the most part, these~have~been unsuccessful.
Po~sibly a major reason such prior commercial attempts have not been~successful has been due to an inability to produce such teeth economically, while retaining acceptable aesthetics with practical adaptability to .
dental laboratory utilization. The p~esent invention has overcome this difficulty in what is submitted to t)e a practical and aesthetical}y acceptable product.
Although the full arch sets o~ artificial teeth employed in the present invention comprises the subject of i3~3 .. .. . . . . . . . .. . ..

another related application, reference to details of such teeth is appropriate herein~ One of the advantageous featuxes of the sets of tee~h has been the repositioning of many of the teeth from the angles normally chosen ~vr a to~th arxangement for artificial dentures so that the teeth can ~e mass-produced in rigid molds. This has involved reshaping the teeth to maintain a pleasing aesthetic appearance, as well as realigning them.
The anterior teeth, including the central and lateral incisors, for example, have the facial or labial surfaces thereof slanting outward at the incisal edges so the same can be wi~hdrawn from a rigid mold without leavinc3 a partinc3 line on such labial surfaces. The posterior teeth have their facial or buccal surfaces slanting inward toward the occ1usal.surfaces so they may be withdrawn from another area of the mold without leaving a parting line. The canines are treated in an unusual way by slanting their facial or Iabial surfaces outwardly at the incisal edges in line with the~other anterior teeth, as will now be described in:detail relative o the drawings~

' FULL ARCH SETS OF' ARTIFICIAL TEETH
Referring to:Yig. l:, an~exemplary full arch set of : artificial teeth is illu~trated in top plan view and shows the rLdgelap dep~ess1ons 12 of the four posterior teeth 14 at opposite ides of the set l0, and include first and second molars and first and ~econd bicuspids, together with the six ant~rior teeth at the intermediate portion o~ the arch configuration and comprising a pair of central teeth 16, a pair of lateral teeth 18, and a pair of canines 20, all arra~ged to be molded integrally in rigid molds r such as illustrated in exemplary manner in Fig. 9, and comprising a rigid upper mold 22 and a matching lower mold 24, details of which are described ~$~;3 ~

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to a greater extent ~elow.
To maintain the arch~d configuration of the exemplary set of upper teeth 10, stabiliæing stxut means are attached to the inner surfaces especially of the posterior t~eth and comprise a central member 26 from which radial fingers 28 extend somewhat in octopus manner. It will be noted the fingers 28 taper outwardly from the central member 26, the smaller ends of the fingers being connected to the posterior teeth in a manner that may be xeadily severed therefrom after the stabilizing function of the strut means has ceased, such as when ~he full arch configuration of teeth has been attached to baseplates or other means described hereinafter in detail.~
To provide illustrations of the manner in which the : present invention has effected repositioning of many of the : 15 :teeth from angles normally chosen for a tooth arrangement for an artificial denture, attention is directed to Fig. 2, which ~is a cross-section taken on the line 2-2 of Pig. 1 and : illustrates a:vertical section of a central tooth 16, having a -~ : ridgel~ap depressio~ l~ and~the facial or labial surface 30 20~ sloping or slanting outward~at the incisal~edge 32~ from the ginglval end~34 to facilita e~withdrawing:the molded teeth from a~rigid:mold,:~such as illustrated in exemplary manner in Fig;.: 9 : with respect to:~the lower~mold 24 wherein the~mol~ing~recess;36 : :forms the gingival end 34 of the central teeth 16, for example and iD whlch the surface 38, comprising a series of:adjacent molding cavities, forms the labial faces 30 of~the central teeth. Preerably, the molding cavities 40 and 41 respectively in the lower and upper molds have parting lines at th~ incisal ends of the anterior teeth and occlusal surface~s of the posterior teeth.

i3~3 ~ An exemplary illustration of a substantially conventional artificial central tooth 16' is shown in Fiq. 2a and, as shown in Fig. 2, the labial surface 30' thereof is illustrated wi~h reference to ordinate phantom lines at right angles to each other~ the vertical line being the reference line with respect to the slanting or sloping of the labial surfaces of the teeth. In Fig. 2a, it will be seen that the labial surface 30' of a central tooth slopes inwardly at both the gingival and incisal ends and would present difficulties in u$ilizing a single pair ~f rigid molds in which the parting line is at the incisal ends of the teeth, whereby the exemplary ~ooth shown in Fig. 2a could not be withdrawn from`molds of the type employed to form the ~xemplary ~en~ral tooth 15 shown in Fig. 2.
With re~erence to Figs. 3 and 3a, it will be seen that in Fig. 3, taken on the~line 3-3 of Fiq. 1, a canine or ~so-called "eye tooth" 20 is show~, in which the facial or labial surface 42 slopes ou wardly at the incisaI end 44 and inwardly at the gingival 46, thus~facilitating~the moldlng ~ 20 thereof by r1gid molds, as described above with respect to ~he : ~ central tooth 16, shown:in ~ig. 2;. In contrast, the c~nventional canine:tooth 20~ 9 ~shown in: Fig. 3a, has~ an outward or labial su~face of curved configuration extending inwardly : both at the incisal 44 and gingival 46 and would similarly :
present di~iculties ln the type of rigld molds employed in the invention as described abo~e with respect to Fi;g, 2a, Turning now to the posterior teeth 14, referr~ng to Fig. 4, which is taken on the 11ne 4-4 of Fig. ;1, it will be seen that the outer or buccal surface 48 slopes outwardly at the gingival S0 of posterior tooth 14 and inwardl~ at the ~2~;3~3 occlusal end 52 to facilitate the removal from the molds 22 and 24 r and especially ~he mold 22 and in which the mold s~ctivn 54 forms the occlusal surface 52 of the posterior teeth 14. The above-described slope of the buccal surface 48 in Fig. 4 is illustrated with reference to an exemplary phantom ordinate line to illustrate the sloping arrangement. In contrast, refexring to Fig. 4a in which a conventional similar posterior tooth 14' is shown, it will be seen that the conven~ional buccal surface 48' slopes inwardly somewhat at the ginyi~al end S0 and substantially inward at the outer portion Qf the occlusal sur~ace 52, which arrangement would present difficulties in utilizing molds of the type shown in ~ig. 9. :, . Fig. 5 is an exemplary bottom plan view of a full arch set of upper artificial teeth to illustrate the occlusal and incisal ends of the posterior and anterior teeth, said ~iew being the opposite of that shown in Fig. l. Referring to Fig.
: 6,~ which is a ~ront e;levation of the exemplary full arch set of : ~ : upper artificial teeth, shown in Figs. 1 and 5, i~:will~ be seen in this view that the slope:of the buccal surfaces of the 20 : posterior teeth 1:4 is well illus:trated and it is to be understood hat the~shape~ and especially the outer labial surfaces of the lateral:teeth is substantially slmilar to that ; :o~ the~canine or cuspid teéth 20. Another imp~rtant ~eature o~
the full arch set:of artificial which adapts its use with the invention is also illustrated in Fig. 6 in which it wil.l be seen that pronounced interproximal triangular spaces 56 are illustrated for purposes Qf effecting de5irab-e aesthet~c contours to cause these artificial teeth t:o closely resemble similar surfaces of natural teeth, at least portions o~ said interproximal spaces 56, as well as the gingival end portion of .~ ~ ""~' ' .

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the anterior teeth being partially covered by portions of the denture base material in the finished dentures in a manner to resemble natural gums and teeth.
Referring to Fig. 7, it will be seen that there is illustrated therein a full arch set of upper ar~ificial teeth 10 and a full arch set of lower artificial teeth 58, both shown in side elevation and disposed in operative relationship with respect to each other along an occlusal plane ~0, shown in phantom. Preferably, the incisal edges of the anterior teeth which are ~hown at the left-hand end of ~ig. 7, and the occlusal surfaces of the posterior teeth shown in the right-hand portion of Flg. 7, commonly abut the ~cclusal plane 60 ~ :
:~ and, while the teeth of both types are shaped to closely resemble the outer labial surfaces of the anterior teeth and the outer buccal surfaces of the posterior teeth, the occlusal :
: ~ surfaces of the posterior t0eth, in~particular, preferably are of~the so-caIled flat plane type in which the occlusal surfaces of opposite teeth:are in continuous~or near1y continuous contact. ~ : :
20:: :~: ~ Referri~g to Fig~ 8,: i~ which a: front elevation o~
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the~fu11 set:of artificial~lower teeth 58 is illustrated, it:
will be seen that the~orresponding ~entral teeth 62, lateral teeth 64, and canine or cuspid teeth 66 are respectively ~: : : :
somewhat narrower than the corresponding teeth of the upper ~et : 25 10, a5 ~hown, for example, in Fig. 6, the~eby harmonizing with ::
khis characteristic of natural teeth. The groups ~f four posterior teeth 68, however, as seen from Fîg~ 7, are n~t narrower than the corresponding teeth of t:he upper:set 10.~ In particular, however, it wîll be seen that înterproximal spaces 5~ are provided in the lower set of teeth 58 f3r the:same ;3 ~

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purposes as described above with respect to the corresponding interproximal surface-~ of the upper set of teeth 10.
For purposes of simplifying the molding of full arch sets of artificial teeth, it is preferred, in accordance with the invention, that a relatively simple set of cooperating upper and lower molds 22 and 24 be employed~ However, it is readily possible to use so-called 3-part molds, embodying principles of the type shown in the prior U.S. Patent No.
1,547,643 to Clapp, dated July 28, 1925, and in which there is shown a so-called shader mold which is used for purposes of inçluding on the labial or~front surfaces of the anterior;
teeth, a thin layer of more transparent plastic material than ; ~ that with which the main body of each tooth is formed for purposes of simulating more closely natural teeth which have a~
: outer layer of more transparent plastic which simulates the enamel portion of the tooth, and to this end,:the exemplary molds shown:in Fig. g may be supplemented by a suitable third, _ : : shader mold.~
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SPECIA~ DENTAL AR~ICULATOR
~ 20 Fox purposes~ of fabricating the above-described full : : :: : arch sets o~ ar~ificial teeth into finished dentures, a special and;very simplified type o articulator has been developed, details o~ which~are shown in~Figs. 10-13. Referring , :~ especially to Figs. 10 and ll, the articulator comprises a lower bow or base member 70, which may be disposecl upon any ~uitable ~upporting surface, such as a counter or bench. It is generally triangular in shape, as seen in Fig. 10, and has a c~ntral, somewhat trlangular opening 72 ~ormed therein and a se~uring pin 74~removably extends through aligned:openings;in the portions of the base 70, which are on either .side o~ ~he , ~
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central opening 72, this apparatus being used in conjunction with securing the lower cast or model 76 of a patient's mouth to the base, one exemplary illustration of the same being shown in Figs. 27 and 28.
Extending upwardly from the rear por~ion of the base 70, at opposite side thereof, is a pair of support members 78, such as shown in Figs. 11-15. Said support members have rearwardly e~tending wing-like extensions 80 and bracing fillets R2, shown in Figs. 10 and ll, con~ected to a transverse support bar B4, which is integrally connected at its ends to support members 7a, as best shown ~n ~ig. 14. The purpose of the bar 84 is set forth below.
Hingedly connected to the upper ends of support members 78 i~ an upper b~w or member 86 which also has a somewhat triangularly shaped opening 88, formed somewhat centrally thereof and another securing pin 90 extends transversely through aligned openings extending transversely ::
through opposite side portions of the upper bow at either side ~: of the opening 88. The arrangement jus~ described is for~
~; ~ Z0 purposes of se~uring to~the upper bow 86 an upper cast or model : 92 o~ a patient, one particular example of which is shown ir.
Figs.:26 and 28.~ In Fig. 11, the upper bow 86 is shown in full lines in its normal operative position, while in phantom, the :same is shown in elevated position. A post 94:is mounted for vertical adjustment within an opening in the ~orward portion of upper bow or member 86 as clearly shown in Figs. 10 and 11, adjustmènt being secuxed by a thumb screw 96, and is operable to maintain the upper bow 86 in normal substantially horizontal pos,ition which is parallel to the base 70. An upper extension 98 is connected axially to the post 94 and is fox purposes of ~ f 9 ~6~

holding the upper bow in ~ull-extended, pivotal position, such as shown, for example, in Figs~ 30-36. Similarly, the triangular shape of the extensions 80 on the support members 78 has a lower rearward edge surface 100, by which the ~rticulator may be supported when the surfaces 100 on the opposite support members are disposed on a supporting surace, for any desired purpose~
Although the articulator shown in Fîgs. 10-13 is of a very simple nature, especially as compared to othex more sophisticated articulators which in particular frequently have elaborate adjustable pivot means, the pivot means of~the instant artic~lator permit at least a limited amount of anterior, posterior, and opposite lateral movements of the ~ upper bow or member with respect o the centric position to ~
: 15 permit a desirable amount of milling movements between sets of full arch artificial teeth when respectively supported by the lpper bow 86 and base 70, as described in detail hereinafter, as well as pivotal~movement of the bows about a horizontal xis. Such limited milling movement i5 permitted by details shown~particularly:in Figs. 12 an~ 13, and in which the upper :ends of;the support memhers 78 are each provided with a threaded opening 102 to receive intermediate threaded portions :
of~t~r~aded thumb screws~104,~having knurled knobs 106 on the ~: outer ends thereof and the opposite~ends of said screws having a smooth, cylindrica~ pivot extension 108 of less diameter than : the thre~ded portion 104. Opposite sides of the rear end portion of the upper bow 86 have short elonqated recesses 110 o~ limited length-~and depth within which the pivot extensions 108 ara ~isposed.
The inner ends o~ the xecesses 110 have a central !~
~"J~

~, , i3~

socXet il29 also of limited depth, extending axially inwardly a limited amount. for purposes of receiving the terminal end of the pivot extensions 108 when the thumb screws 104 are threaded to the full permitted extent inwardly, whereby a solely pivotal movement about a transverse axis is afforded the upper bow without milling movement. However, by backins o~:E the thumb screws 104 sufficiently until the ends of the extensions 108 are disposed only in the short recesses 110, said limited amount of milling movement of the upper bow with respect to the base or lower bow may be effected, as can be visualized from the length of the recess 110, shown in Pigs. 12 and 13. This amount of moveme~t is adequate to effect a highly useful and practical milling movement. ~ : :
An important attachment for the articulator cQmprises a mounting table 114 which is planar and preferably triangular in shape as shown in Figs. 16 and la. One surface of the ~ mounting table 114 is provlded with a mounting bar or rib 116, which is parallel:to the rear edge 118 of mounting table 1~14 : and is disposed a limited distance t~erefrom for purposes of ~ 20 having:the hamular notches 120 of~the upper cast 92, see ~ig.
; : 26, positioned thereon to facilitate the alignment and heiyht of said cast wi~h the mounting table 114. This situation has ~ need for a measurement which facilitates the:full positioning (~ o the upper cast ~r model on said table employ~ wedge blocks 122, see Fig. 22~. Said blocks have stepped~faces arranged predetermined distances apart in elevation, in even or odd increments of two millimeters apart, and in view of there being a pair of such wedges respectively with the stepped surfaces, one has surfaces offset one millimeter w.ith respect to steps on the other, and thereby selectively provide, Eor~example, one E~ .;~

~ 5i3~;3 --~
. .
l' `.

millimeter adjustments in the stepped surfaces while using OAe or the other of the wedge blocks 122, such use being illustrated and described hereinafter relati~e to additional figures.
The aforementivned measurement referred to immediately above can be effected by an iDstrument such as that illustrated in Figs. 19-21 and comprising an elongated bar 124 at the upper end of which a lateral blade 126 is formed, the bar accommodating a slide 128, which , at its upper end, has another blade 130 extendlng laterally therefrom and a viewing opening 132 ~lso being ormed in said ~lide for purposes of observation of ~cale indicia 134 formed on one ~a~e of the b~r 124, as clearly shown in the upper portion of Fig. 20.:~
Referring to Fig. 19, there~is fragmentarily illustrated therein, in phantom, a sectional outline of an upper lip 136 of a patient and the central forward portion 138 of the gum o~ the upper jaw of a patient, which is known as the incisive papilla.
: The dis~ance between the lower edge of the upper lip ~ : :
and the incisive ~apilla is measured on the scale 134 and is ~indicated by the~reference:lin~e 1~0 on ~he slide 128, and the : reading opposite ~he reference line indicates the distance the : incisive papilla on the forward portion 138' of the upper cast, shown in Pig.~ 26,~must~be~spaced from th upper~surface of the ; : support table 1~14, as viewed in Fig. ll, and from which the 25:~ support bar 116 extends perpendLcularly. Such spacing is accompl:ished by utilizing a sel~cted stepped surface of one vf the wedge blocks 122 which corresponds to said measurem~nt and results in a positioning of the upper cast on the support table, as shown ln Fig. 30.
Hamular notches in the upper casts or models of a i~ ~z~ . ;
_ ~ _ ~ ,~,f,, 3 ~--.. . , . , . . , _ .
.

pa~ient's upper jaw have been used he:retofore inciden~ to leveling the cast relative to a bench top in a dental laboratory. As far as is known, howevex, such notches have not been used heretofore in conjunction with a positioning or support table. Also, while the aforementioned measurement ~etween the incisive papilla of an upper cast or model and the lower edge of the upper lip of a patient has been use~
heretofore to establish a plane in the anterior region of a cast, such measurement has not been used as ~ar as known to position said incisive papilla of the cast relative to a support table, especially in ~onjunction with the stated use of the hamular notches of the cast. Such an overall combinatlon is believed to be nvvel:and highly effeckiYe to produce ~
satisfactory artificial dentures by the further procedures described herein.
~he mounting table 114 is detachably and reversibly : positionable upon th~ lower bow or base 70 o~ the articulator ~ and the support members 78 which are affixed to ~he rear edge:
:
; ~: : of the base 70 at opposite sides thereof by any suitable meanst such as scre~s 142. When the tab~le i~ to be mounted:as shown :::: in Fig.:11, with the mounting bar 116 extending uppermost, a reversible supporting pin~1~4 is threadably connected to the forward end of the table by being threaded into a suitabl~ hole to support the forward end upon base 70. The rearward portion of ta~le 114 rests upon transverse support bar 84, as shown ~ragmentarily in Fig. 14, and thereby supports the mounting bar 116 uppermost for disposition of the upper cast 92 thereon in the manner shown in Fig. 30. In order to prevent sidewise movement o~ the table with respect to the base 79, Opposite ~t~,i 30 sides of the rearward portion o~ the table 114 arle provided ~ %3 -- W-- :

31G;3 .... . . .. . . . .

with notches 146, which receive 1ugs 'L48 formed on the inner surfaces of the support members 78. Said members also are provided with notches 150, see Fig. 14, through which the rear edge of the table 114 may pass incident to disposing the notches 146 with respect to the lugs 148.
~he table 114 is reversible in order that the planar surface 152 thereon may be disposed uppexmost, when, for example, the upper full arch set of artificial teeth 10 is to be mounted operatively with respect to the upper cast or model : 10 92 by procedures described hereinafter. To accomplish this, table 114 is removed from the position shown in:Fig. 11 and is reversed to dispose the mounting bar 116 in a depending : position, such~as shown, for example, in Figs. 36-38, the supporting pin 144 being unthreaded from the position shown on the kable in Fig~ ll, and is threaded into the opposite surface of the table and thus, disposes the table 114 in opposite parallel posit:ion with r~spect to the base 70 from that shown : DENTURE PORMING METHOD AND PROCESS
~ In~he introductory por~tion of thi~s specification,~
reference has~een made to the formation of upper and :lower~
casts~or:models 92~and 76~which~, convention~ally, are formed by dentist and;used by the dentist or sent~to a laboratory for formation of the dentures~by the employment o~ such casts or models. In addition, the dentist conventional1y provides a:jaw relation bite record 154, whlch CoDSiStS of a p1astic material of certain wax compositions~or the like ~nd, a~ter being softened, is capable o~ being inserted into a ~atient's mouth between the upper and lower jaws and especially the gum ~1 30 portions thereof to impress said gums into the materia1 and, ;~ ~;f :

i363 a~ter cooling to stabilize the bite record, form~ at least a temporary relationship record to establish the relative vertical positions of t~e natural jaws with respect to ea~ch other and upon which artificial dentures are to be mounted so as to fit comforta~ly and be operable o masticate food while be1ng retained solely by suction or gravity upon the patlent's : gums.
It is obvious that natural teeth in human dentures space the gums vertically apart a predetermined distance, and it is preferable that this distance or one very close to it in measurement~be used to space apart the upper and lower casts ~r models shown in Fig.~28 by means of the ~aw relation~bite~
: record lS4.~Having been furnished e1ther the upper:and lower~
casts or impressions by ~which the casts~may;be ormed,~as~wel;1;
15 ~ as:~the:jaw relation~bite record,~ a dentist or technician:is;:~
then~in position to:proceed in accordance:with the:~principles of this invention to~fabricate a;~set of~upper and: lower ~

:
dentur&s which;~;include r&sp&otively fu11 arch upper~and 10w&r sets~of~rti:ficial teeth iO and 58,~suc~as~shown in Fig.:1~-8, by means of;the~following:~steps,~illustrated~sequentially:in~

Having~obtained the:~r&qu1red vertical spacing betwe&n the incisive~papilla~ l38 and~the~lower~edge:~of;the~upper~lip~
136,~the:upper~c&st~or:mod&1;~92~is~mount&d~in the:artlcu1a~tor, 25 ~:~as~shown in~Fig.:30~,:ln which;the~:upper~bow or member 86 has been~pivota1ly~moved~180 to~the 1noperative position shown~ in ~ig. 30, and thereby enable the upper cast ~r model 92 to be mounted upon the table 114, with ~he hamular notches:120 positioned upon the support bar 116, and a:selec~ecl:~stepped ~: :
: 30 surface of the wedge:block 1~2 has~been placed~upor1 the:table , ,. : :
~,,, i3~3 114 to support the incisive papilla the required distance from the upper surface of the table, as determined by the measuring : instrument of Figs. 19-21~ so as to establish the upper cast in a position to r~eeive the full arch set of upper artificial 5 teeth by the procedures subsequently.descri}:~ed.
The next step is fihown in Fig. 31, in which 1the upper bow has been pivoted to operative position with respect to the table 114 by the upper bow being accurately positioned a~ove base 70 by means o~ the post 94, whereupon settable attaching material 156, such as plaster, dental stone, or other gypsum-like material is disposed within the openi~g~88 of~the upper bow so as to surround the :pin 90 and be attached to~the : surface 158 of upper ca~t 92. The material 156 will ~ :
operatively.cura in a short period o~ time, such as twenty : 15 minutes, more or less, following which the steps shown in Flg.
32 take place, whlch comprises~removing the table 114 and wed~e block 122, as well as pivoting the-~upper bow 86 to inoperative position.
The foregoing~step i5 followed:by attachlng~the jaw :20 : relation bité record 154~ to:the~u~per cast or model 92 and also~
attaching the lower cast 76~to the bite record l:54, as shown in igO 33. In;~this position,~the lower cast 76 is in position to be:attached~to the~base:70:~of the articulator by~additional~:
settable material 160 of the~same~ type as material 156, and 5 ~ :illustrated in Fig. 34. Usually,:when applying~the material ~, ;::~ 160: to the bas~ 70:and lo~er~cast 76, the assembly shown in Fig. 33 is manually reversed while holding the upper bow 86 in base 70 in the relationship shown in Fig. 33 so that the material 160;may be poured through the openin~ 72, see Fig. Il, of base 70 and into engagement with the surface 162 of the ~ ~~ ~

, .

-.. ..

lower cast and then permitting the material to ~et within the opening 72 and around the securing pin 74, which brings us to the step shown in Fig. 35, in which the upper bow 86 is pivDted t~ inoperative position with the upper cast 92 is secured S thereto. The bite record 154 is xemoved from both casts and the lower cast 76 with its attaching means 160 is removed from the base 70.
~he next step comprises replacing the mounting table 114 in revexsed position to that shown in ~ig. 11, ~or example, as well as Pigs. 30 and 31, in order to dispose the planar surfa~e 152 of said table uppermost, as shown in Flg. 36, it ~einy understood that the supporting pin 144 also i5 reversed so as to engage base 70 and thereby support the planar surface 152 in proper position as shown in Fig. 37 $o receive a full arch set of upper artificial teeth~10 with the inclsal and~
occlusal surfaces of the anterior and posterior teeth preci ely upon the upper surface 152 and in desired position with respect to the upper cast or model 92, as indicated ~y the spaced indicating lines 162 and:median line 154 inscribed upon the 20 ~ surface:152 of the tabl~e 114, as~shown in ~fulI lines in:~ig.

The ~oregoing poSitlOniDg of~the upper set of t~eeth lO~is accomplished by use~of the upper~oast or model 92 when~:

:: : : :
: supported by the upper bow or member 86 as shown in~Fig, 37, but:before the teeth lO~are placed~as shown:. Chiefly by ~ighting, an imaginary perpendicular line is dropped from the incisive papilla of the upper cast or model 92 to~the lines 162 and centered on median line 164 and marked by pencil or otherwise. The lines 162 preferably are spaced metrically and preerably at 1 to 4 mm spacing, most preferably 2 mm spaclng.

. .

The mark then is moved forwardly about 4 or 6 mm to determine the location for the front anterior surface of the central teeth 16 of the upper set of teeth 10. With the set of teeth held firmly in the latter position, such as shown in Fig. 37, attaching material 168, or vther material referred to hereinafter, is appliPd between the set of teeth and the upper cast or model 92 to connect them together for further procedure.
Furthe;r to a.~sist in such posi~ioninq of the full arch set of teeth 10 upon the surface 152 of table 114, an adjustable positioning member 166, shown in exemplary manner in Figs. 17 and 18, may be employed with rPspect to the gradient lines 162 to~have the foremost anterlor portion of the full arch set of teeth l~ disposed against member 166 and thereby ~15 prevent movement of the teeth especially along the median line 164, for example, and thereby accurately positlon the teeth for applying removable atta~hlng material 168, such as soft sticky wax, between the teeth~and the upper cast 92 upon which, in ; aocordance~:with usual procedure, a~usually thin conf.iguration ;20 ; of~baseplate~mat~rial,:~such as~w~ax and/or plastic, or mixtures thereof, o~conventional type, has been~shaped to conform to : the gum surface~of~the cast but~is readlly removable therefrom ; and to which the attaching material 168 readily;adheres between : : the ~ingival por~ions of the full arch set of teeth~lO and:the :
baseplate, which is not shown in detail but is of conventional type as aforesaid.:

Initially, small lumps of the attaching mater~al 168 may be used as descxibed and ultimately, additional wax mater.ial is aesthetically shaped upon the baseplate material on the gum portion o~ the cast 92, in order to prov:ide desirable t'~ 2 ~

3~;3 _~

.. .. .. .

contour surfaces extending upward from the teeth and r~sembling natural gums in the finished denture to be formed from the process being described.
Following the steps &hown in Fig. 38, and referring:
to Fig. 39, it will be seen that the next step comprises pivoting the upper bow 86 to the position shown in Fig. 39, followed by removing the mounting table 114 and replacing the lower cast 76 and its attachin~ material to ~he base 70, whereupon the upper bow 8~ is returned to the operative position above base 70. When the lower cast 76 is in the position shown with respect to base 70 in Fig. 40, the full arch set of iower teeth 58 is placed closely ln Dcclusio~n relative to the full arch set of upper teeth 10 so that they : ~ are in the proper relationship, such as shown in exemplary manner in Fig. 7, ~or example, whereupon the lower set of teeth 58 is at least temporarlly attached to the sheet-like baseplate material prevlously conformed to the lower ~ast 76 by means~o ~ addltional lumps:of remo~rable~attaching ma~erial 170, or ;~ otherwise, in order~to sta~ilize the set of lower teeth~58 with 20 ~ respect to the cast~76. Thereaf~er, as descrlbed above ln : : regard o the upper~set of~:teeth 10, an aesthetic application of additional~wax or similar materlal is added to the teeth and baseplate material to resemble natural gums, where~y the lower : set of teeth~and baseplate on the lower denture 76 axe finallzed a~ to shape to resemble natural gums. Preferably, at this stage of the proeess, the radial fingers 28 o~ the strut means are severed from the full arch sets of the teeth,--just prior to the finishing the final contour.inq of the wax.
After the upper~and lower sets of ~ull areh arti~icial teeth have been secured respectively to the ;3 a~

.

baseplates upon the casts or models, both of the baseplate configurations with the ar~ifi~ial sets of teeth attached thereto may or may not be remove~ and fitted o the patient's gum~ for a try-in,. and if necessary, desirable adjustments may be made.
. In the ~oregoing, refexence has been made to the adjustable positioning membex 166, shown in ~igs. 17 and 18.
An exemplary type thereof is shown therein and may be made of metal or plastic and has a curved upright flange which abuts the forward anterior portion of the upper full arch set of teeth 10, especially to prevent forward movement ~hereof while attaching the same to the baseplate on the gum portion of upper cast or model 92, as can be visualized from ~igs. 37:and 38, :
especially. The member 166 is slotted:to receive a thumb screw lS 161 which is threaded into a hole in table 114 and after adjus~ment of the curved portion relative to the indicating lines 162, the screw is tightened to secure the desired position of the member upon table 114.
After th2 finishing wax has been added~betwenn the~
20 : respective sets of full arch teeth and the respective : baseplates attached thereto ~o that the surface of the waxed-up : products resemble the natural gums and teeth of artificial gums desired to be produced, the connected sets of;teeth and ~: ~aseplat~s are;removed with the casts or model5 to which they ::
are removably attached and then are~processed in a ~onventional manner to produce the ~inished dentures comprising the full arch sets of artificial teeth integrally connec;ted to conventional denture base material which is inserted into the molding cavities formed by the conventioncll processing methods.
normally employed for such purposes.

3~3 ~--Such conventional meth~ds include investing the axed-up teeth and baseplates and the upper and lower casts or models in so-called dental stone or si.milar material mounted in flasks of well-known type, followed by boiling out the xemovable material ~f wax and otherwise while leaving the artificial teeth, and especially the occlusal and incisal portions thereof embedded in the dental stone, thereby forming the cavity of the desired shape of the denture base to be attached to the teeth. ~iscous denture base material then is placed by conventional apparatus and means into such cavity for bo~ding to the ridgelap surfaces of the p~sterior and anterlor tee-th and overlapping of ~ome of the gingival surfaces of said teeth:, as well as a certain amount extending at least partially : into the interproximal areas 56 between adjacent teeth and clearly illustrated in Figs. 6-8, all resulting in the formation of imitation gums contoured to resemble natural gums and attachable to the gum portions of the upper and lower iaws of the patient and retained thereagainst by suction andior ~ gravlty, particularly in~regard to the Iower denture.~ See Fig.
: 42 for an exemplary illustration of such dentures.
-: The completed dentures are removed ~rom the dental stone~comprising the molds into which the denture base material : is injected, ~nd after suitable polishing of conventional type, :~ the completed dentures are ready for try-ins an:d actual use.
; ~ : 25 Lastly,~referring to ~ig. ~1, when the finished dentures are completed, it is sometimes found that a limited amount of milling between the upper and lower set5 of teeth is desirable in order that the incisal and occlusal surfaces thereof may suitably occlude and thus dispose the teeth and especially the occlusal and incisal surfaces thereo~ as shown ,~ .

~53~;3 ... . .

in Fig. 7, ~or example, alon~ a common occlusal plane 6~. To accomplish this in accordance with the present invention, the kno~s lD6 of the thumb screws ~6 are reversely screwed to back off the screws sufficiently to ~isengage the pivot extensions S 108 from the central sockets 112 to an extent such as shown in phantom in Fig. 13, whereupon the pivot extension~ 108 are disposed entirely within the short recesses 110 and thereby permit limited lateral movem0nt of the upper bow with respect to the upper ends of the support members 78, as well AS the base 70, and thùs permit milling between the incisal and occlusal surfaces of the sets of teeth 10 and 58 to a desired extenf, such movement bei~g indicated in exemplary manner ~y - the direction arrows 172 in Fig. 41.
Referrlng ~o Fig. 24, an exemplary subs~itu~e support 174 is shown~for use upon one type of a conventional articulator in the event it is not desired to employ the articulator of the present invention and the mounting table 114 thereofO The support 174 has a planar support surface 176 and :a mounting bar:178 for positioning hamular notches~of the~upper ~: : 20~ casts. Vertioally adjustable base members 180 at opposite sides permit adjustment of surface 176~relative to the lower : : bow or base of~such conventional articulat~r.
In PigO~25, another;attachment 182 is shown for use : ~ with another well-known type of artioulator ~nd is provided:
; : 25 with a mounting bar 1~4 to be engaged by hamular notches of an upper dental cast.
Prom the foregoing r it will be seen that the mechanical elements of the invention and the ful:L arch sets of upper and lower arti~icial teeth result in producing desirable and highly acceptable artificial dentures with a minimum of ~536~

operational steps and especially in the saving of time over that required to individually mount artificsal teeth in wax in accordance with normal procedures and especially including interdigitation thereof, when necessary. ~urther, by utilizin pre-formed full arch sets of upper and lower artifioial teeth, mismounting of the teeth and otherwise possibly misaligning th same i5 avoided, compared to the possibility of mismounting an misaligning that can occur when utilizing individual artificia teeth in the preparation of dentures.
The foregoing description has referred to the preparation of the arrangement of convention~1, removable wax and baseplate material a~d the sets of full arch teeth attache~
thereto being processed into finished dentures by ~onventional techniques such as investing the waxed models and full arch teeth in dental "stone" and ~'boiling out" the removable wax an( baseplate material to form a cavity into which conventional denture base matexial is inserted for attachment to the teeth which are partially embedded in the dental "stone. n The present invention is not to be restrict~d to the above-: 20 describ~d techniques, however, in that further improvementsalso are included in the invention which include the~use o~
certain composition~s comprislng manually or ~echanically applicable, actinic Iight-curable baseplate and denture base : : material in lieu of remo~able:wax and conventiona~ baseplate ~ 25 materials described above. These composi~ions msy be quickly cured, thereby further to shorten the time required to form : finished dentures in accordanc~:with the following description.
One example o~ a composition that is moldable to a - denture base form and is hardenable and cured by exposure to visible light was prepared ~rom the Pollowing ingredients in , ~ ~
~,h ~ .

~ 3~3 64053-133 the manner described hereinbelow:

39~44 Urethane dimethacrylate (Reaction product of hydroxyethyl methacrylate and

2,2,4-trimethylhexyl-1,6-diisocyanate) 2.57 1,6-Hexanediol dimethacrylate ( HDDMA~
0.13 Campiloroquinone (CQ) 0.59 Reaction product of dimethylaminoethy?
methacrylate and methacrylic acid (DMAEMA--MAA) 42.10 poly ~methyl methacrylate-co-ethylene dimethacrylate 99.8:0.2) a polymer supplied by L.D. Caulk Company (Polymer is in substantially spherical beads the shape resulting from its suspension polymerization.
At least 50~ by weight of the beads have average diameters of less than 50 microns.

, The polymer~was prepared from methyl ; methacrylate and ethylene dimethacrylate by suspension polymerization*).

0O07 red acetate fibers 0.03 pigments 15.07: fomed silica inorganic filler (Aerosil R972~a product;of Degusqa) ~ ~ ;

First CQ wa~s dissolved i:n HDDMA and then mixed wlth ths DMAEMA-MAA snd urethsne dlmethacrylste. Th~e * ~he~polym~r was prepared accordlng to the teaching of ~;30 UOSO Patent 4,396,~476.
`~

i. :

3~3 resulting liquid solution was charged to a double planetary mixer heated to 45C and mixed under 20 mm Hg pressure. Next the polymer, and pigments and fibers were blended in a V-Cone Blender. The polymer blend was added and mixed under 20 mm pressure~ The temperature was increased to 55C and ~he fumed silica was ~ 3S~
,~
(~
,., added in three i~crements of about equal size and mixed under 130 mm pressure each time. This produced a visible light curable (VLC) putty-paste which is then fur~her treated to remove excess entrapped air by placing the put~y in a canister and subjecting it to ~ mm mercury pressure and then ~o high pressure in ~ hydraulic press. The putty was then extruded through Delrin Dies using a ram extruder into a sheet having a size of 0~1 inch x 2 5/B inches and a rod having a diameter of 0.375inch. The sheet and rod were then cut into lengths of about four inches.
By putty it is meant a viscous material ~hat can be deformed mechanically (manually) and ~ill at least temporari~y hold the shape i~to which it has been deformed or molded.
The~initial setup of the upper:and lower stone models ~15 and determination of the relative position of the uppèr full arch set of teeth in an actic~lator was~the same as previously described and illustrated with respect to Figs. 30 through 37.
In this way,~ the dental models are precisely positioned in space~in a:manner allowing th~ir removal and return to : ~ 20~ precisely~the~same~position. ~However, ~rom that stage forward ~: ~ the~process did ~differ in:the manner now to be described.
;The dental model~ Wa8 removed~from the~ aforesaid :: :precise positio~ by opening the articulatox ~ the position : shown in Fig. 36~ The molding surface Qf the dental model was : ~ 25 then coated wlth a release or separator system which consisted of Part A and Part B: :
(1) Part A o~ the system which functions as ~ sealer for the gypsum mold or model was brushed over the entire gypsum model surface. The solution dried very quickly leav~ng an almost invisible film on the surface. Part ~ was prepared ~rom 3~ ~
..$~

~2~5~3~;3 _~

the following ingredients:
0.68% Hydroxyethyl cellu].ose ~Na~rosol 25V HR, Hercules, In~.) 97~82 Water NonylphenyI ethoxylate surfactant tMakon lO, Stepan Chemical Company~
0.20 0.1% FD&C Blue ~1 Dye in water 1.00 Preservative (Glydant, Glyco, Inc.) The above ingredients were mixed together at ambient conditions and the resulting solution, herPin called Part A, was a clear, blue colored solution with a vlscosity of 354 centipoises at 22C. ~Brookfield, model RVT, t2 Spindle, 100 rpm~.
: 12) ~hen, Part B of the separator system, which ~: functions as a surface cure promoter was brushed over the coated surface, covering only the areas to be:in contact with VLC Denture Resin. The wet model was then dried until tack free under a hair dryer. Part B of the separator system was prepared from;the following ingredients:
: ; 41.00~ Polyviny~ pyrrolidone (Plasdone:K 29~32,:
20 ~ GAF Corporatio~n) 58.~23 Water 0.~0~45~Silicone antifoam ~SAG 471:,~ ~nlon Carbide Corporation): : :
.225 Surfactant (Makon lO,:Stepan Chemical Corporation) 0.50 Sodium ~enzoate ~: The above inyredients were mixed together at a~bient eo~ditions and the resulting solution was a very viscous clear yellow colored liquid with a viscosity of 850 centipoises at 22C l~2 3~ spindle, 20 rpm).

3~3 A sheet of the previously described VLC putty, 3.5" long, was conformed to the desired shape on the upper dental model by pressing it into shape by hand using the techniques employed in conventiona;L denture baseplate shaping with wax, but without heat softening the VLC putty. The sheet was thereby formed or molded into a denture baseplate for the upper denture.
The baseplate was trimmed and then hardened in two minutes of light cure. Any arrangement providing a good cure can be used. The total light flux varied from 100-130 mw/cm2 (at 400-500 nm) on the surface of the baseplate during the cure.
A full arch set of upper teeth was prepared for attachment to the upper denture baseplate by first roughening the ridgelap portion with a dental bur to assure the very best bond and then coating the ridgelap with a bonding agent. The VLC bonding agent was prepared from the following ingredients:
QM 657 (Rohm & Haas) 30.00 g Methyl Methacrylate 30.00 g Acrylic Acid 6.00 g 1,6 Hexanediol ~imethacrylate 10.00 g Dimethylaminoneopentyl Acrylate-Methacrylic Acid (DMANPA MAA) 1.56 g Camphoroquinone (CQ) 0.30 g Uvithane 782 (Morton-Thiokol~ 63.00 g The ingredients were mixed in an amber bottle ;~
_~ _ ~ .
b: ~ `;

3'~3 64053-l33 at ambient conditions and then heated at 60C until completely homogeneous.
The VLC Tooth Bonding Agent was brushed on the area of the teeth to be bonded and allowed to stand for two minutes. Then, the VLC Tooth Bonding Agent was light cured on the teeth by two minutes expo~ure, in the manner described for curing the VLC denture baseplate composition.
,~ The reason the bonding agent is important as described is that the full arch set of teeth is made from the currently preferred polymer composition as taught in U.S.P. 4,396,377 which has been assigned to the as~ignee of the present application. The teeth were thus comprised of acrylic plastic and without the use of mechanical locking means, a good chemical bond is preferred to assure a permanent securement of the teeth to the denture baseplate.
The full arch set of upper teeth was placed in position adjacent to the denture baseplate in a measured .
precise position measured in relation to the dental model of the upper jaw prior to the forming of the denture baseplate thereon. The position simulates a functional and aesthetic alignment of the full arch set of teeth relative to the denture baseplate. This was done by using the guiding indicia on the occlusion table~114 as described with respect to Fig. 37 earlier.
The upper dental model was then reinstalled in the arti~culator with the upper dental baseplate in positlon on it~with the separator or release coat between ~; 30 the denture '~

' ' '' . ' ' ~ . ' ' ' 3~3 . .

baseplate and the model. The rod-shaped VLC putty was used as a t~cking put~y to initially secure the denture baseplate and teeth together. The tacking quantity of putty was initially applied to the denture baseplate in the rod shape around the ridge of the baseplate and curved around in the general configuration of the ~ull arch set of teeth. Th~ tacking quantity of putty is such that it will later be covered up and thus need not in itself offer a ~ully aesthetic appearance when placed, although it is preferable to and was in fact initially shaped by hand and flattened out against the denture baseplate where it contacts or engages the baseplate. ; ~
With the full arch set of teeth in their adjacent : position as previou~sly described, the portion o~ the~ ~
articulator mounting the dental model having:the shaped denture baseplate engaged thereon was hingedly closed as prevlously described with respect to Fig. 38. The tacking quantity of putty was trapped:between the closing baseplate and the ridgelap of the teeth. The teeth were thereby engaged with the tacklng putty~
~ The dental baseplatè will be understood to have ~een `:
engaged with the full arch~;set of teeth with the teeth ~ :
malntained in their~precise measu~red position when~;the model was~returned~to~its~previously~ e~stablished precise position.
The teeth were maintained in position by being held by hand:
against adjustable positioning:member 166.
: : : : :
. After removing the baseplate model and teeth from the : artieulator, the tacking putty was hardened by act:inic yisible liyht to rlgldly attach and secure the fu11 arch set of teeth to the denture baseplate providing the positioning of the full arch s0t o~ teeth for receipt of the gum simu1at:ing putty which i3~

.. . . .
'`

corresponds to the previously referred to adjacent position.
This hardening was by curing through the engagement of the putty with ~isible actinic light for two minutes in the manner previously described respecting the curing of the upper denture baseplate. In this manner the full arch set of teeth is positioned.
Next the facial and lingual aspects of the denture were ~inished with additional xod putty. To do this the upper jaw model was again secured to the upper articulator bow member 85 via the securing pin 90 and the articulator was opened and turned around and tipped back on its rear edge stand surface lO0 for ease of working. The putty, which was of the same visible light curable composition as that used for the baseplate and the tackinq putty~ was molded about the teeth at their gingival ends to simulate gum tissue. The gum simulating application of putty was by hand using instruments of the type commonly employed for haping wax to simulate gum tissue in a dental lab. The material worked well using standard techniques. ~Ma~erial was~also added to the back of the full ~ axch~set o~ teeth to ~erge the~ gingival ends of the teeth with the denture base~plate more~aesthetlcally~and ~o provide a~
better feel for~the~denture wearer.
herea;fter, an~oxygen~barrle~r layer o~ the ~ ~
compo~sition of sur~ac~ cure promoter portion Part B of the two part separator layer previously described was applied as a top coating over the exposed surfaces of the putty of the gum simulating portions and the other portions of~the dentu~e, and the denture was cured with visible light for our minutes in the manner descr1bed above. This hardened the putty molded about the teeth at their gingival ends by subjecting the putty ~ 4~

3~3 ~=

..

to actinic visible light engagement.
The upper and the lower jaw models were then secured in precise position in the articulator via pins 90 and 74 respectively, with the articulator in the open position as shown in Fig. 36 but with the occlusion mounting table 114 removed as illustrated in Fig. 39. The lower jaw position, which was established earlier, related ~ixedly to the position of the upper ~aw model and in the position in which it is to be when the upper denture is fu11y closed with the full arch set of upper teeth on the occlusion table 114.
The molding surfaces of the lower jaw ~odel were :
coated with the same two-part release coat system as was~used on the upper model and in the same manner. A sheet of the same ~ visible light curable polymeric composition usPd to make the upper denture baseplate was conformed to the desired shape on the lower jaw model over the release coat in the manner practiced with the upper denture preparation. The model with the~;formed denture baseplate thexeon was then removed from the articulator and ~he polymeric composition was hardened by :d 20 engaging it with visible light in the manner described respecting the upper dènture baseplate. The lower model with ; ~ the thus formed lower denture baseplate was then resecured:~in the articulator with pin 74.
: 'rhe articulator was then closed, bringing the upper denture just above the lower denture basepla~e. Next the lower full arch set of teeth was a}igned in occlusion with the upper full arch set of teeth after the upper full arch set of teeth which have already been set in their precise poe;ition, If the lower set of teeth cannot initially be fully c~ccluded with the upper set of teeth and aligned with the lower denture baseplate -- A~ --3~;3 for proper moun~ing, necessary adjustments in aecordance with usual dental prosthetic techniques are used to adjust the occluded closing in proper relation with the upper denture i~
its earlier established precise position~ Some grinding vf the 5 ridgelap and other adjustments may be needed to obtain proper fit. In the specific sequence of operation here described, some grinding was required ~o properly position the teeth.
The ~ull arch set of lower teeth were of the same composition as the upper teeth and were prepared for attachment to the lower denture baseplate by roughening and applying a bonding agent in the same manner as the upper full arch set of teeth.
Next a tacXing quantity of the same rod-shaped putty used with respect to the upper denture was curved around in the : : :
general configuration of the intended ~ower full arch set of teeth. The articulator was then swung partiaily closed pressing the lower full arch set of teeth into the tackiny :
~putt~on the~lower denture baseplate while the full arch set of teeth~were held in occlùsion with the upper full arch set of teeth by hand~
There`after, the lower model with the lower denture baseplate thereon wlth~the teeth attached was removed and the tacklng putty was hardened with visible light ln the man~er described respec~ing the upper denture construction. The tacking putty was hardened in engagement with the lower full arch set of teeth.
Nex~, visible light curable putty was molded ~bout the gingival ends of the teeth in the same general manner described respecting the preparation of the upper denture.
The exposed surfaces on the Iower denture mode:L were coated ~,Si/ ~

i3~;3 with an oxygen barrier layer as described respecti~g the upper denture preparation. Then, the visible light ~urable composition putty around the gingival ends of the teeth simulating the gum tissue and at the back of the arch at the gingival ends was hardened with visible light as described respecting the upper dentures preparation, As a final procedure, the lower denture still mounted on the model is returned to the articulator and the thu~b screws 104 are backed out and the articulator i9 used to mill the occlusal surfaces to enhance better occlusion. An abrasive of the type usually used for milling for plastic artificial teeth was used and the upper bow was then moved back and for~h and from side to side under hand pressure.
After the milling procedure, the upper and lower dentures were removed from their respective s~one models using substantially conventional techniques which involved sectioning the stone models with a saw and pulling the pieces of the stone models away from the respective dentures. The borders of the upper and the~lower dentures were then trimmed and any needed ; 20 smoothing o~ imperfections~was carried out as is conventional.
Then~, the entire~de;nture surfaces were polished in conventional `:
~ manner using pumice, rag wheeIs, and buffing compounds. The :
surfaces were then washed with tap water and dried with a paper towel and found~to be dry, shiny,~and tack free. The dentures were th~n clinically fitted by pl~acing them in a patient's mouth and found to give an excellent and true ~it and to have a good, aesthetic appearance and to provida good ~unction.both in mastication of food and speech.
In accordance with the principles of the inventivn, a full arch set of arti~icial teeth comprises in integral ;3 combination, a pair of similar centra:l teeth each respectively flanked on one side by a lateral tooth, the lateral teeth each being flanked on one side by a canine tooth, and each canine tooth being flanked at one side by a set of four posterior teeth each comprising a pair of bicuspid teeth next to the canine teeth~ and a pair of molar teeth extending from one end of each pair of bicuspid teeth. In some situations, it may be possi~le to vary the exact anatomy of the full arch set of teeth described so long as the aesthetic value of a full arch set of teeth i5 achieved. Of course, in this day of novelty items, variations to obtain special effects are not to be understood as departing from the true contribution of the present:inve~tion.
I 15 : In accordance with another preferred embodiment of the invention, dentures, including partial dentures, may be formed employing actinic, preferably visible, light curable materials as described hereinbefore. Thus, dental prostheses capable of replacing one or mor~ teeth in the ~20 mouth of:a partiall.y or wholly ede~tulous individual can ~ be formed in accordance with this invention. The ~
; : : procedures which have been;discussed hereinbefore~are ;~ generally applicable~to this procedure with modifications as described~ Thus, a negative~impresslon of~ at least a :~: 25 :portion~of the jaw o~ a patient hav:ing at least one :
edentulous portion is made and~employed to prepare a model of the jaw portion in a manner substantially identical to the procedure described for ~he making of the full jaw models. As with that procedure, the li.ght curable, moldable denture base material is applied to the model and .., ,.. ~i, conformed thereto. In accordance with the present embodiment, however, the actinic, preferably visible, light curable material is caused to conform to the edentulous portion of the model should the same be less than the entirety of the model. As will be appreciated by those of ordinary skill in the art of preparin~ partial dentures, such partial dentures are conventionally and preferably prepared so as to be able to be affixed to one or more tooth structures naturally occuring in the jaw of a patient. Thus, the present embodiment preferably employs embedding of a rigid framework adapted for afflxation to at least one natural tooth structure of the patient's jaw into the denture base material. The denture base material is then exposed to actinic, preferably visible, light for a time suf;ficient to harden the material to form a partial denture base. If, as is preferred, the rigid framework has been embedded in the uncured denture base material, then it is rigidly and permanently affixed in the cured structure following irradiation. Thus, the denture base may comprise either -~ the cured denture base material or the cured denture base material having the rigid framework embedded therein.
: ~: : ~ :
~ It is also preferred to employ such frameworks for~r~estorations involving~full~dentures in which event the framework would be free standing and not cGnnected to a natural tooth.
ndividual teeth are affixed to the formed denture base in accordance with a novel technique. Thus, the teeth are first mova~ly affixed to the denture base through the intermediation of additional quantities of actinic light curable, moldable denture base material.

, 3~3 _~

Such curable material is either applied to the denture base, to the teeth, or to both and the teeth and denture base are placed into contact through the intermediation of the curable material. As will be appreciated, the curable ma~erial has substantial thixotropicity and is generally sufficient to support the teeth on the denture base, albeit in a temporary and movable fashio~.
The teeth are then irreversibly affixed to the denture base through a process which is denominated as "tackingn. Small proportions of the actinic, preferably visible, light curable composition which removably affix the teeth to the denture base are caused to be polymerized by exposure to light. These minor proportions ~et or cure into a hardened state and provlde rigid, adhesive fixturin~ of the individual teeth to the denture base.
Prior to the irreversible affixation of teeth, the same are caused to be oriented or aligned inter se or oriented with respect to the denture base or both. Thus, the ~_ tacking process can be seen to provide a means for the ~20 carefal orientation of the teeth. The resuIt of this ~~ procedure is a denture having improved fit, physical appearance and conforma~t;ion to specifica ion.
The irreversible affixation of the teeth khrough :
~; ~ the tacking pr~ocedure of this invention is preera~1y accomplished seriatim. Thus,~teeth are sequentially , , ~ , oriented with respect to each other and the denture base and tacked 1n sequence. Hand-held, visible liqht curing sources such as the PRISMAR light distributed by the L.

. , D. Caulk Co., a division o~ Dentsply International Inc., are ideaIly suited for this purpose~ Accordingly, the , ~ :

a363 practioner need only direct visible light from the PRISMAR light or other visible tiqht curing source upon a minor proportion or proportions of the visible light curable composition removably affixin~ the teeth to the denture base. This effectuates tacking of a tooth to the denture base by the polymerization and hardening of the minor proportion of the curable material exposed to the visible light. The polymerization need not be complete in accordance with this step; such curing need by only sufficient to provide irreversible affixation.
The present procedure contemplates alternatively forming a continuous ridqe of curable material and then individually placing separate teeth in general alignment and thereafter individually finely adjusting the teeth or 15 ~ individually mounting~ each tooth with a small independent uantity of curable material, as well as other positioning procedurs~ However, in each instance, there is at least :
one separate step by which different individual teeth are ~ ~ irreversibly fixed by exposure of a portion of the actlnic 20~ light curable ma~erial to~actinic light.
Following~the lrreversib1e affixatio~n of all of the teeth to the denture base, the balance~of the vlslble light~curable materlal is curèd or hardened by expos~ing the same to visible~ligh~t~for a p~eriod of ~time su~fl~ient 25 ~ to~effeatuate the~cure. In accordance~w1th other;~
preferred embodiments~ is~desirable to add sdditional quantities of~this actlnia, prefe~ably visible, light curable, moldable;material to the region of the denture base and the irreversibly affixed teeth and to cause the ~2~ 3 same to assume the shape of gingival tissue This is conveniently accomplished through a modeling technique as described hereinbefore.
It is preferred to employ bonding agents in accordance with this embodiment. Thus, a bonding agent as described above is preferably applied to the artificial teeth prior to their insertion and affixation to the formed denture base.
It is also preferred to employ oxygen inhibition or barrier coatings on the visible light curable materials prior to the final, substantially full hardening of the light curable material by irradiation with visible light.
This application i~proves the surface curing character-istics of the material and leads to an improved product~
Such coatings are compositions adapted for excludinq a substantial proportion of oxygen from the surface of the denture base composition subsequent to the irreversible affixation but prior to the full hardening step.
Thosa of ordinary skill in the art will appreciate that numerous variations on the foregoing J- embodiments for the preparation of full and partial dentures can bé employed in accordance with the spirit of the instant invention. Thus, varying numhers of teeth,~
, ~ ~ varying configurations of partial denture, varying means~
:
for~affixation of the denture or prostheses in the mouth of a patient, other modifications can be employed without deviating from the spirit of the invention.
~ y reference to Fig. 43, a partial denture in accordànce with the foreqoinq preferred embodiment i5 f 3~;3 ~

depicted. A model of a jaw portion 200 having an edentulous region on one side thereof 201 has a layer of visible light curable, moldable denture base material 202 applied to it, and in ~articular to the edentulous portion. A rigid framework 204, partially shown in cutaway, has been embedded in the denture base material.
The framework has a portion 206 which is adapted for affixatioll to at least one natural tooth structure oE the jaw.
In Fig. 43, the visible light curable material having the rigid framework embedded therein has been hardened by exposure to visible li~ht and comprises the denture base. Artificial teeth 208 and 210 have been removably affixed to the denture base through the application of an additional quantity of visible light curable, moldable denture base material 212 in the region where the teeth contact the denture base. The additional quantity of polymerizable material covers portions of the teeth shown in phantom. Areas 214 and 216 represent areas where visible light can be caused to irradiate minor - ~ proportions of the additionaI quantity of denture base material 212 to effect tacking of the teeth to the denture base. I~ will be noted that the portions 21~ and 216 are much less than a major proportion of the entire, 2~5 ~ additional quanti~y of visible light curable material.
Followln~ substantially complete hardening through overall irradiation of visible light, a finished denture~will result.
It is, of course, prefera~le to model arti~icial gingivae, to employ bonding compositions to improve ~i5i363 _~

bonding of teeth to the denture base, and to employ composîtions adapted for excluding substantial proportions of oxygen from the surface of the denture base material preparatory to the curing.
While the present invention has been described with the overall generic invention highlighted, it will be obvious to those skilled in the art tha~ the species of the invention have wide application~ Also, while in accordance with the present statutes what is at present considered to be the preferred embodiment of the invention has been described, it will be obvious to those ski:Lled in the art that numerous changes and modifications may be made therein without departlng from the invention, and it is t-herefore aimed in the appended claims to cover all such equivalent variations as fall within the true spirit and scope o~ the invention.

~f

Claims (14)

THE EMBODIMENTS OF THE INVENTION IN WHICH AN EXCLUSIVE
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:

1. A method of forming a denture having a plurality of artificial teeth comprising the steps of:
(a) using negative impressions of at least a portion of a jaw of a patient having at least one edentulous portion to make therefrom a model of said jaw portion;
(b) applying to the model actinic light curable, moldable, denture base material to conform the same to the edentulous portion of the model;
(c) exposing the denture base material to actinic fight for a time sufficient to harden said material to form a denture base;
(d) movably affixing a plurality of artificial teeth to the denture base by applying to the denture base or to the teeth or both an additional quantity of actinic light curable, moldable, denture base material and contacting said denture base with said teeth;
(e) irreversibly affixing the teeth to the denture base by exposing minor proportions of the added actinic light curable material to actinic light for a time sufficient to cure said minor portions, sand irreversible affixation being insufficient to cure a major proportion of the added material, and (f) substantially fully hardening said material by irradiating it with actinic light.

2. The method of claim 1 further comprising applying a further quantity of actinic light curable, moldable, denture base material to the denture base subsequent to the irreversible affixation of the teeth, and molding the same into a replica of gingival tissue prior to the substantially full hardening step.

3. The method of claim 1 further comprising applying to said additional quantity of actinic light curable, moldable, denture base material of step (d), a composition adapted for excluding a substantial portion of oxygen from the surface of said denture base composition prior to the substantially full hardening of step (f).

4. The method of claim 1 wherein said irreversible affixation is preceded by orientation of individual teeth inter se and with respect to the denture base and the exposure of minor proportions is conducted seriatim to the teeth.

5. The method of claim l further comprising embedding in said denture base material a rigid framework adapted for affixation to at least one natural tooth structure of said jaw prior to the exposure to form the denture base.

6. The method of claim 1 wherein said actinic light is visible light.

7. A method of forming a denture having a plurality of artificial teeth comprising the steps of:
(a) forming a denture base;
(b) movably affixing at least one tooth but less than all of said plurality of teeth to a denture base by applying to said denture base or said at least one tooth or both, a quantity of actinic light curable, moldable denture material and joining said at least one tooth to said denture base with said denture material;
(c) finely adjusting said at least one tooth by moving said at least one tooth and said denture material joining it to said denture base;
(d) exposing at least a portion of said actinic light curable, moldable, denture material to actinic light sufficient to irreversibly affix said finely adjusted at least one tooth;
(e) movably affixing at least one other tooth to said denture base by applying to said denture base or said other tooth or both a quantity of actinic light curable, moldable, denture material and joining said other tooth to said denture base with said denture material;
(f) finely adjusting said other tooth by moving said other tooth and said denture material joining it to said denture base; and (g) as a step separate from step (d), exposing at least a portion of said actinic light curable, moldable, denture material to actinic light sufficient to irreversibly affix said finely adjusted other tooth.

8. The method of claim 7 further comprising repeating, in sequence, steps (e), (f) and (g) until all of said plurality of teeth have been irreversibly affixed to the denture base.

9. The method of claim 7 further comprising substantially fully hardening the denture material by irradiating it with actinic light.

10. The method of claim 7 wherein each of steps (d) and (g) result in the curing of less than a major proportion of the moldable material.

11. The method of claim 7 wherein the actinic light is visible light.

12. The method of claim 8 further comprising applying to the denture material a composition adapted for excluding a substantial portion of oxygen from the surface of said material.

13. The method of claim 9 further comprising applying to the denture material a composition adapted for excluding a substantial portion of oxygen from the surface of said material prior to the substantially fully hardening.

14. The method of claim 7 further comprising providing artificial gingival tissue adjacent said plurality of teeth formed from actinic light curable material.