❖ Definition of connectors: those parts of a FPD that join the individual retainers and

pontics together.

❖ Types:

1- Rigid connectors:
● Made by:
- Casting: rigid connectors must be shaped and incorporated into the wax pattern
after the individual retainers and pontics have been completed to final contour.

- Soldering
- Welding
- Milling

● Allow no movement.

Function: unite retainers and pontics in which the entire load is directly transferred to the
abutments.

Contraindications:
➔ Existing diastema is to be preserved.
➔ Tilted abutment.
➔ Long span bridge (Law of Beams and for common path of insertion).

About Indications Advantages Setbacks

Cast They are shaped in wax as part of a They’re restricted to Convenient The fit of individual
Connectors multiunit wax pattern (one-piece simple restorations → minimized lab retainers in long span
casting). (3-5 units). steps. bridges may be affected
because distortion results
*It’s advisable to Less liability to when a multiunit wax
restrict cast distortion of wax pattern is removed from
connectors to pattern handling the die.
complete coverage (if properly
restorations, which handled). *Access to the proximal
can be gripped margin pattern is impeded,
bucco-lingually. and the pattern cannot be
held proximally during
removal from the die.

*Partial coverage wax

patterns are easily
distorted when they are
part of a single-cast FPD.

Soldered - All FPD parts (including the Long-span bridge 1) Retainers are Requires an additional
Connectors

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 connectors) are waxed to the to transfer wax shaped and step, compared to a one-
final shape, but then sectioned pattern without adjusted piece casting.
with a thin ribbon saw (the distortion. individually with
pontic is left connected to the improved access
retainer from one side to not for finishing
alter the fit) → the surfaces to procedures.
be joined will be flat, parallel,
and with a controlled distance 2) No distortion of
apart. wax pattern.
➔ A recommended even gap
width is: 0.25 mm.

- Then they’re sprued & cast as

regular → solder.

- Cleanliness of the surfaces is very

important to allow good wetting by
the solder alloy.

- A flux is used to clean the metal

surfaces, allowing easier flow of the
liquid filler metal (soldering metal)
over the base material.
★ Dirt or surface oxides on the
connector surfaces can
reduce wetting and affect
soldering.

★ The parts being joined are

not melted during soldering,
but must be thoroughly wet
by liquified solder.

Loop - The connectors consist of a loop Rarely used, but --- ---
Connectors on the lingual aspect of the sometimes are
prosthesis that connects adjacent required when an
retainers/pontics. existing diastema
is to be maintained
- The loop may be cast from sprue in the planned fixed
wax that is circular in cross section prosthesis.
or shaped from platinum-gold-
palladium alloy wire.

- Meticulous (careful) design is so

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 important so that plaque control will
not be impeded/prevented.

2- Non-rigid connectors: they permit limited movement (stress-breaker).

It is the segmenting of the large, complex FPDs into shorter components →
easier to replace or repair.
● Precision attachment: key & keyway.
● Non-precision attachment: occlusal and cingulum rests.
● Cross pin & wing
● Split connectors

● Indications: difficult common path of insertion or when there’s a concern about an

abutment’s prognosis.

There are two approaches to design the non-rigid connector:

1. In which the the design is incorporated in the wax pattern stage:
- Consists of a mortise prepared within the contours of the retainer, and a tenon
attached to the pontic.

- The mortise (keyway) is usually placed on the distal surface of the anterior
retainer.
➔ The alignment of the cylindrically shaped mortise is critical; it must
parallel the path of withdrawal of the distal retainer.
**Paralleling is normally done by a dental surveyor.

- The mortise is shaped so its path of insertion permits concurrent seating of the
tenon (key) and its corresponding retainer.

- The retainer is the part cemented, not the pontic.

2. Another approach is to use prefabricated plastic components for mortise and tenon of a
non-rigid connector.

Precision attachment:
- What is an attachment?
➔ Connector that consists of two or more components:
◆ One connected to abutment,
◆ Other connected to the prosthesis.

The precision attachment is an accurately fitting interlocking used for:

➢ Combining FPD (e.g. pier abutment situation, difficult common path of insertion)
➢ Attaching removable restoration:

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 ○ RPD
○ Removable bridge.

➢ Custom-made (cast/milled).
➢ Readymade.

➔ Involves mortise and tenon. The mortise is prepared within the contour of the retainer.
The tenon fits into the mortise and is attached to the pontic on one side (Fixed-
supported), or attached to the pontic on both sides (Removable bridge), or placed in the
RPD or overdenture.

Advantages:
- To decrease the load on abutment teeth.
- To overcome problems in malalignment.
- High retention and stability.

Types:
- Extracoronal attachments.
- Intracoronal attachments.
- Bars, studs, and magnets.

Disadvantages:
- Additional cost.
- Wear of the components.
- Space problems.
- Special requirements in abutments.

Non-precision non-rigid connectors:

- Inlay-retained bridge
- Fixed-supported bridge: occlusal or cingulum rests.

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 Connector Design

Size Shape Position

- They should be sufficiently large to - Buccolingually it should be elliptical in shape, Connectors are normally placed
withstand stresses and prevent to provide strength. towards the lingual, to improve
distortion or fracture during function. appearance.
- Tissue surface should be highly polished and
● If small → failure. curved, to facilitate cleansing.
● If too large → small
embrasures → hygiene is - Mesiodistally, it is shaped to create a smooth
impeded → periodontal transition from one component to another.
breakdown by time.

★ Adequate access must be available for oral hygiene aids cervical to the connector.
★ For esthetic FPDs, large connector may result in metal display of the metal connector,
leading to bad esthetics and patient dissatisfaction.
★ Q: Why are elliptical-shaped connectors preferred?
➔ Elliptical shaped connectors are the strongest if the major axis of the ellipse is
parallel to the direction of the applied force.
★ Q: Give reason why the gingival aspect (tissue surface) of the connector should
be curved.
➔ To prevent excessive display of metal.
➔ Ease of cleaning.

Requirements for connectors

➔ As large as possible (mechanical principles)

➔ As lingual as possible (esthetic principles)
➔ As away from the gingiva as possible (biological principles)

1. Must be sufficiently wide to provide strength during function, but not too wide to interfere
with effective plaque control, promoting periodontal breakdown by time.

2. Should have adequate embrasure space and occupy the normal anatomic interproximal
contact areas,
➔ Because encroaching on the embrasure restricts access for oral hygiene aids.
➔ Also, to improve appearance without significantly affecting plaque control
(anterior connectors are normally placed toward the lingual).

3. Should be curved buccolingually to facilitate cleansing and provide strength (cross

section: elliptical shape).

● Ideally, there should be a cross-section of min. 7 mm² (2.5 x 2.5 mm) in the anterior
region and min. 9 mm² in the posterior region.

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● Height is more important than width.
- Doubling height → strength x8
- Doubling width → strength x2

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 Joining Process

★ Soldering: the filler metal (that joins the metals together) has a melting point below
450°C (less than that of parent metal). Solders are melted using heat from a
temperature-controlled soldering iron.

★ Welding: joining metals by melting the base metal (by heat or pressure), causing fusion.

★ Brazing: filler metal has a melting point above 450°C but always below that of the base
material to be joined. The filler metal is protected by flux.
○ Brazing is considered a high-temperature version of soldering.
○ Not commonly used with dentistry.

➢ In both soldering and brazing, the filler material must be protected by flux. Also, the parts
being joined are not melted, but a filler material is melted and flowed between the two
parts.

○ If the soldering gap width increases → soldering accuracy decreases.

○ If the soldering gap width decreases → prevent proper solder flow and
lead to incomplete or weak joints.

★ Laser welding: using the strongest instantaneous thermal effect of laser beam,
concentrated on a minute spot.
- Laser assembly of fixed prosthesis reported higher strength and reduced
corrosion in comparison to conventional soldering.

Advantages Disadvantages

- The heat affected zone is small, so - Hazardous

the alloy properties will be unaffected. - Costly
- Less distortion. - Technique sensitive
- Higher strength & accuracy.
- Relatively easy and time saving.
- Can be done directly on the cast, even
near veneering.

Applications of Soldering:
1. Assembling a long span FPD.
2. To overcome distortion in multiunit cast FPD.
3. Building up proximal contacts.
4. Repairing casting voids, perforations, or broken joints.
5. Cutting and rejoining of ill-fitted/distorted bridge (components which do not seat
together).
6. Joining separate units of a fixed partial denture made of dissimilar metals.

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 ★ Shortcoming of soldering: requires an additional step in comparison to one
piece casting.

Soldering Techniques
a) Freehand soldering:
- Involves the addition of solder to the defective area of the restoration.
- Adding proximal contact
- Void or pit and hole repair.
Steps of freehand soldering: heating of restoration → antiflux → flux → alloy then
reheating.

b) Investment soldering:
- Used when accurate alignment is needed for the parts to be joined.
- Involves the construction of a “solder assembly” that holds the prosthesis units
during soldering.
- Must have a soldering index: plaster or special self-cure acrylic resin (duralay).
❏ Duralay: no shrinkage, dimensionally stable, fast setting, clean burnout.

★ Index is made for the occlusal surfaces of the FPD to capture the relative relationship of
the individual FPD components inside the patient’s mouth and then transferred to a
laboratory. This procedure can also be performed on an accurate master cast (recording
correct relationship).

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 ★ Heating method for investment soldering technique: torch.
★ All-metal FPDs → low-fusing solder (conventional soldering).
★ Metal-ceramic FPDs → postceramic or preceramic soldering.

Soldering All-Metal FPDs (refer to the handout).

Soldering prerequisites:
● Clean metallic surfaces.
● With walls as parallel as possible.
● A soldering gap (0.05-0.25 mm).
● Framework elements that have been evenly preheated to the processing temperature.
● Flux that will dissolve the oxides.

Factors affecting solder joint strength:

1. Soldering gap width
2. Solder alloy (types & requirements)
3. Soldering flux and antiflux
4. Soldering investment
5. Heat source

1. Soldering Gap Width:

● Increasing the gap width → solidification shrinkage → undersize FPD
mesiodistally.
● Extremely small gap width can prevent proper solder flow and lead to an
incomplete or weak joint (porosity and distortion).
● An even soldering gap of about 0.25 mm is recommended → compensate
for solder solidification shrinkage.

2. Solder alloy:
❖ Requirements:
● Have lower fusion temperature than the parent alloy (fuse safely below
the sag or creep temperature of the casting to be soldered. The solder
should possess a fusion temperature that is about 80-100° below that of
the metal to be soldered).
● Have high tarnish and corrosion resistance (this is determined by a
solder’s noble or precious content and its Ag/Cu ratio. In addition, if the
compositions of the solder and work piece differ, galvanic corrosion may
occur).
● Flow freely (flow increases by silver and decreases by copper).
● Have high strength property (greater than that of the soldered parent
metal).
● Should be non-pitting.
● To match the color of the units to be soldered.

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 ❖ Types:
● Modern casting alloys are metallurgically complex, it’s recommended now to use
specially formulated solders.
○ Group I: traditional gold solders (according to gold content).
○ Group II: special solders (base metals) (According to fusion temperature).

About Advantages Disadvantages

Pre-ceramic - High-fusing solders: fusion temperature Allows the connected - Contouring the proximal
Solders is 60°C below that of the parent metal prosthesis to be tried in embrasures may be difficult.
being soldered. the mouth in the
unglazed state. Any - A disadvantage results from
- The framework is assembled before adjustment can be made having to apply the porcelain to a
porcelain application → all margins to the porcelain, which longer structure, which needs
should be protected by embedding fuses at a lower support during firing to prevent
them in the investment to avoid temperature than the high-temperature deformation or
overheating. preceramic soldered sag.
connector. ➔ Sag can be a problem
- Requires a gas-oxygen torch. with high-gold content
- Can be quenched after ceramic alloys because
soldering. they have a lower melting
range.
➔ High palladium content or
base metal alloys exhibit
little sag during firing.

Post-ceramic - Low fusing solders: flow below the - Because the proximal Strong but brittle joints (as the
Solders pyroplastic range of porcelain. areas are shaped before solder cannot be quenched after
soldering, a soldering).
- All porcelain construction steps must be postsoldered connector
completed before soldering, including final looks more natural than
staining and glazing (the regular gold will a presoldered or cast
melt if it’s subjected to high temperatures connector.
needed for porcelain application).
- Firing supports are not
- The framework is assembled after the needed because sag is
porcelain is applied. not a problem (the
length of the individual
- Necessary when regular gold and metal- components are
ceramic units are combined in a FPD. shorter).

- Performed either in a porcelain furnace

or with a gas-air torch.

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3. Flux & Antiflux
● Soldering flux is applied to a metal surface to remove oxides or prevent their
formation.
★ Why? → When oxides are removed, the solder is free to wet and
spread over the clean metal surface.

● Modifiers:
○ Ag (silver) increases flow, while Cu (copper) decreases the flow of the
solder.

● Types:
○ Borax glass: used with gold alloys because of its high affinity for copper
oxides.
- It’s composed of borax glass (55 parts), boric acid (35 parts), and
silica (10 parts).
- These ingredients are fused together and then ground into
powder.

○ Fluoride flux: used with non-gold based alloys, to dissolve stable oxides
of chromium, cobalt, and nickel.

● Availability: powder, liquid, or paste form. The paste is popular because it can
be easily placed and confined.

N.B: Avoid all fluxes from contacting porcelain-veneered surfaces or it might

cause pitting and porcelain discoloration.

★ None of the new fluxes are totally capable of preventing oxide formation during heating
of the base metal or non noble alloys.

● Antiflux:
○ Uses: limit the spreading of the solder alloy.
○ It’s placed on the casting before flux application.

■ Graphite pencil: a disadvantage of graphite is that carbon

evaporates at high temperatures, leaving the area unprotected.

■
Iron oxide (rouge)/ Iomoxide: more reliable.
● It’s made of iron oxide in a solvent (either chloroform or
turpentine) that can be painted with a small brush on the
casting.
4. Soldering investment:
● Similar in composition to casting investment (gypsum & phosphate-bonded).

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 ● Quartz (refractory component) investments are better than
cristobalites because of lower thermal expansion → avoid unwanted
excessive separation of the parts to be joined which might cause an ill-
fitting restoration.

● Invested units expand during heating, so the units must be correctly gapped so
that they don’t touch.
➔ If the work units are allowed to touch, distortion and porous and
inadequate joints result.
➔ Alternatively, excessive gap spaces cause undersized mesiodistal FPD
widths because of the solder solidification shrinkage.

Explanation: The refractory component in casting investment carries unwanted

thermal expansion → excessively separates the units to be joined → undersized MD
FPD widths, because of the solder solidification shrinkage.
➔ So, soldering investment contains fused quartz, which is the lowest thermally-expanding
form of silica.

● Properties:
- High strength.
- Should withstand heat without cracking.
- Gypsum and phosphate bonded investments may be used.
- For post-ceramic soldering, phosphate may cause loss of surface glaze.

5. Heating source:

Advantages/Disadvantages Precautions

Torch Soldering Advantage: maximum visibility, - Using the reducing portion (3rd zone) of the flame and applying
(most commonly accessibility, and control. an appropriate flux prevents oxidation of the joint surfaces.
used)
- The flame is never concentrated in one area, but kept in
- Low heat constant motion for even heat distribution (Uneven heat
soldering: gas-air distribution can result in fracture).
torch.
- When a gas-air torch is used to melt the solder, metal-ceramic
- High heat restorations are preheated in an oven to avoid cracking of the
soldering: gas- porcelain veneer.
oxygen torch.

Oven Soldering Advantages: uniform - Can be done under vacuum or in air inside a porcelain furnace.
temperature & simultaneous
heating. - A piece of solder is placed at the joint space and the casting and
solder are heated simultaneously.

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Infrared Soldering Shortcoming: locating the focal - Can be used for low-fusing connectors, as well as preceramic
center of the light on the spot to soldered joints.
be soldered, otherwise: cold joint
- Produces concentrated heating by optically collecting infrared
(no soldering).
energy and directing it to the connector area.

- Infrared light is used as a heat source.

Laser Welding Previously discussed.

Soldering Process
1. Separating the parts to be soldered.
2. Cleaning and polishing of components.
3. Assembly of units in soldering investment using soldering index.
4. Invest (soldering gap 0.05-0.25 mm).
5. Selection of alloy.
6. Application of flux and antiflux.
7. Preheating the FPD assembly.
8. Placement of solder.
9. Application of flame.
10. Cooling of assembly.
11. Finishing.

★ Testing of solder joint for strength: manually by hand.

Notes
● Split connectors/ cross-pin and wing connectors: for non parallel abutments.

● Long span FPDs are better cast as multiple (sectioned) units, then assembled by
soldering to produce a better fit due to:
➔ Liability to distortion during wax pattern removal from the working die system
(using sectioned working model increases the chances of inaccuracy).
➔ The longer the bridge, the more the chances of distortion and inaccuracy.

● Abutments should have a passive fit.

● Rule of 27: it signifies the minimum load capacity (i.e. load the FPD will be able to
carry).
➢ Occlusocervical height² x width (the result should be more than 27).
- Can be measured with a periodontal probe or digitally.

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 Troubleshooting

A prosthesis that fails to fit 1. Failure to maintain proper relation between parts.
2. Improper heating of the assembly.
3. Improper proximal gap distance.
4. Presence of foreign materials (as investment) on the fitting surface.

Lack of integrity Joints with pits or voids are not acceptable.

- Small surface defects are reshaped if possible, taking care not to affect the
size of the joint.

- The presence of large voids or internal porosity dictates reinvesting the

prosthesis and reflowing the joint and a small amount of new solder should
be added.

Poor size or form Inadequate size of the joint affects its strength.
- An undersized joint is corrected by reinvesting and additional solder
is added.
- An oversized joint is corrected by grinding, as it will interfere with
proper oral hygiene measures.

Foreign body inclusion - Lack of integrity.

Any foreign body inclusion should be removed (if this results in an undersized joint,
reinvesting and addition of new solder is done).

Joint fracture during testing This could be due to joint porosity caused by improper soldering technique.
- Reinvesting is done after the torn connector is smoothened.

Porcelain discolorations This could be due to:

1. Excessive flux
2. Contaminated furnace
3. Direct contact of the flame with porcelain near the solder joint.

Localized surface roughness It is often due to investment contacting the porcelain surface.

Loss of glaze 1. Excessive flux

2. Phosphate-bonded investment is used as soldering investment without
protection of porcelain.

Porcelain cracking 1. Rapid heating.

2. Rapid cooling.
3. Accidentally, a drop of water touched it (common in postceramic soldering).

Good luck :)
Loujine Elrafey

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