Creating a dental crown is a complex process that requires precise attention to detail and expertise. To construct a crown, a variety of materials can be used, including metal, ceramic, porcelain, and plastics, or sometimes, combinations of these materials.
The process to create a porcelain crown specifically involves several key steps that ensure a perfect fit and natural appearance. While the methods used to make a porcelain crown are quite common, the approach can vary slightly depending on the materials chosen. This behind-the-scenes journey reveals the intricate steps that go into making a crown that not only restores the functionality of a tooth but also provides a long-lasting, aesthetically pleasing result.
A Technological and Artistic Marvel
Modern porcelain crowns have become a technological and artistic marvel in the field of cosmetic dentistry. These high-quality crowns offer both successful reconstructive and aesthetic solutions, closely resembling authentic teeth. In the process, advanced Virginia dental lab techs and proficient ceramists work to craft the crowns, often attaching them to implant posts for a seamless fit.
The Process Begins in the Laboratory
After taking an impression, the laboratory begins the work of creating the dental crown. The plaster teeth are separated, and the individual tooth mold in need of restoration is scanned into a computer to capture its precise dimensions. This data is then sent to the factory, which is equipped with a technologically-advanced setup. A computerized machine at the factory will pour plaster into cylindrical molds, forming blanks. Once the plaster blanks have hardened, the process of making the tooth begins, shaping the mold into a functional restoration.
Milling, Shaping, and Finishing the Tooth
After the machine receives the scanned data from the impression, it begins the milling process to carve out the contours of the finished tooth. At this stage, the tooth is intentionally made 20% to 30% larger than necessary, accounting for material shrinkage that will occur later. The liquid ceramic is then applied to the plaster tooth, and as the ceramic hardens, it forms a gleaming, natural finish,
making it look indistinguishable from a genuine tooth. The machine then moves on to orienting the tooth with others by pouring ceramic powder into new molds over the plaster tooth. These molds are placed on a rod and submerged into a water-filled chamber. When the chamber lid is sealed, the water pressure increases, solidifying each ceramic tooth
Shaping and Fitting the Restoration
The restoration is carefully chiseled to match the plastered tooth, which forms the base for the ceramic shell of the crown. This shell is then lifted off the plastered tooth and is referred to as the coping. To ensure stability, the coping is exposed to a high temperature, causing it to shrink to the proper size. Once cooled, a plastic replica of the original tooth is created using the computer scan, and the new shell is tested for a precise fitting over the tooth to ensure everything aligns perfectly.
Painting and Firing the Crown
Once the shell is complete, it is sent to the factory and then the lab, where colored porcelain is painted onto it in layers. A skilled ceramist, an artist in every sense of the word, may apply up to 15 layers of porcelain to ensure it perfectly matches the variations of the surrounding teeth. This labor-intensive process contributes significantly to the cost of a high-quality crown. Afterward, the crown is fired, making the porcelain more solid throughout. If needed, hand contouring is done, and the final touch is a clear, ceramic gloss to give the crown a smooth, shiny finish.