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What impression materials work best for digital denture workflows?

The short answer is use the same materials as conventional/traditional dentures

 

Impression Material Material Benefits for Denture Patient Record Capture

Polyvinyl Siloxane (PVS)
Most Recommended
  • Excellent dimensional stability over time (important if shipping to the laboratory)
  • Superior detail reproduction captures fine anatomical landmarks
  • Minimal distortion during setting and after removal
  • Good tear strength prevents damage during handling
  • Compatible with all scanning technologies
  • Sets in 4-6 minutes, allowing adequate working time
  • Available in multiple viscosities (light, medium, heavy body)
  • Preferred material for most digital denture workflows

Polyether
Alternative Option
  • Very good dimensional stability comparable to PVS
  • Excellent stiffness when set provides accurate support
  • Slightly less tear strength than PVS
  • The more rigid material can be difficult to remove in severe undercuts
  • Absorbs moisture if not scanned promptly (less ideal for shipping)
  • Shorter working time than PVS (typically 3-4 minutes)
  • Appropriate when immediate scanning is available

Alginate
Acceptable with Limitations
  • Dimensional stability limited (must be poured or scanned within 30 minutes)
  • Detail reproduction adequate but inferior to elastomers
  • Very economical material cost
  • Fast setting (2-3 minutes) is good for patients with gag reflex
  • Cannot be shipped to the laboratory (must be poured immediately)
  • Acceptable for preliminary impressions or record bases
  • Can work for final impressions if immediately poured and scanned

Impression Compound
Specialized Use
  • Used primarily for border molding procedures
  • Not used alone for final impressions
  • Can be combined with a wash impression technique
  • Traditional material with a proven track record
  • Requires flame softening (technique-sensitive)
  • Good for severe undercuts or difficult anatomy

 

Key Principles Regardless of Material:

  • Complete anatomical landmark capture is essential
  • Tuberosities, incisive papilla, and retromolar pads must be visible
  • Border extensions must reach vestibular depth
  • No voids or pulls in critical supporting areas
  • Adequate thickness throughout (minimum 2-3mm)

 

Special record considerations for digital denture workflows:

  • If shipping impressions: use PVS for dimensional stability during transport
  • If scanning in-house immediately: polyether acceptable
  • If laboratory scanning: any material is acceptable if properly sent
  • Avoid alginate if there is more than a 1-hour delay before pouring/scanning

 

Border molding material considerations for denture records:

  • Heavy body PVS is excellent for border molding (good viscosity and strength)
  • Can use impression compound for the traditional technique
  • Polyether is too stiff for functional border molding in most cases
  • Alginate inappropriate for border molding (inadequate stability)

 

Material considerations for a wash impression technique:

  • Light body or medium body PVS is ideal for wash impressions
  • Provides intimate tissue detail while maintaining support
  • Can be used over border-molded heavy body or compound
  • Appropriate viscosity flows into tissue detail without displacing tissues

 

Material considerations in relation to scanning  compatibility:

  • All materials scan well with benchtop scanners when properly prepared
  • Powder spraying may be needed for shiny or translucent materials
  • Alginate scans well if not dehydrated (within 30 minutes of removal)
  • Stone casts scan excellently (may be better than impression scanning)

 

Cost-benefit analysis between PVS and Alginate:

  • PVS costs more per impression ($15-25) but provides the best reliability
  • Alginate is very economical ($2-5 per impression) but is time-sensitive
  • For digital workflows with shipping, invest in PVS for peace of mind
  • Failed impressions cost more in remake time than material savings

 

Clinical material recommendations by denture workflow:

Denture Workflow Recommended Material
Reference denture PVS in existing denture as custom tray
New denture with conventional records PVS final impressions
Immediate denture PVS or polyether depending on turnaround needs
Record bases Alginate acceptable for preliminary impressions 

 

Additional Resources

For more information concerning the digital dentures:

 

Contact Information

For help with a digital denture solution for your next case, contact ROE Dental Laboratory: