DGSHAPE DG DWX-52D Dental Milling Machine User Manual

DG DWX-52D Dental Milling Machine
User Manual
Supported models: DWX-52D / DWX-52DC / DWX-52DCi

DG DWX-52D Dental Milling Machine

Thank you very much for purchasing this product.

• To ensure safe use with a full understanding of this machine’s performance, please be sure to read through this manual completely.
• Reproduction, citation, or translation, in whole or in part, of this manual is prohibited without the express written consent of DGSHAPE Corporation.
• The contents of this operation manual and the specifications of this product are subject to change without notice.
• DGSHAPE Corporation assumes no responsibility for any damage that may occur through use of this product, regardless of any failure to perform on the part of this product or of any errors in this document. Damage includes but is not limited to damage caused by the specifications or performance of the product, damage caused by non-use of the product, and damage caused by deliverables obtained through use of this product. Such damage can be either direct or indirect.

Company names and product names are trademarks or registered trademarks of their respective holders.
Copyright © 2021 – 2022 DGSHAPE Corporation
http://www.dgshape.com/
FA03450
R3-221229

Before Use

Checking the Included Items
The following items are included with the kit. Make sure they are all present and accounted for.*1: ZRB-150D, ZPB-100D, ZPB-50D, ZPB-30D
MEMO
The CA-DK2-FX, CA-DK2-TR, and dedicated milling burs can be purchased separately.

Items to Prepare Yourself

• Items included with the machine

Materials, equipment, etc.

• Cold-cured resin or Heat-cured resin
• Pressure pot
• Stand for adjusting the position of the polymerizing resin (This is used when adjusting the resin height during polymerization.)
• Spatula (This is used when mixing together the powder and the liquid.)
• Container (This is used when mixing together the powder and the liquid.)
• Lidded container (This is used when mixing together the heat-cured resin powder and the liquid.)
• Tissue paper (This is used to absorb the heat-cured resin’s excess liquid layers.)
• Polyethylene sheet (This is used to keep fingers from coming into contact with the heat-cured resin’s excess liquid layers.)
• Vibrator (This is used to extract air bubbles from the container after the powder and the liquid have been mixed together.)
• Heat-resistant acrylic resin adhesive (This is used to affix the CA-DK2-FX, the CA-DK2-TR, and artificial teeth.)
• Brush/eye dropper (This is used to apply adhesive.)
• Artificial teeth

Advance Preparation

Add water to the pressure pot and prepare a stand that will position the CA- DK2-FX (cold-cured) or the silicone stand (heatcured) within the range indicated by the water level gradations. 

Usage Method

This section explains how to create dentures with this kit. Cold-cured resin or heat-cured resin may be used.
There are two workflows: the Denture Base workflow in which the resin is polymerized before the denture base is milled and the artificial teeth are affixed and the Removable Denture workflow in which the mold for the artificial teeth is milled and arranged and the resin is polymerized before the complete denture (full denture) is milled. The work procedure varies depending on the resin and method used.
Cold-cured resin
• Denture Base Workflow (P. 5)• Removable Denture Workflow (P. 8) Heat-cured resin
• Denture Base Workflow (P. 12) • Removable Denture Workflow (P. 17)

Cold-cured resin

Denture Base Workflow
In this method, polymerize the resin, and then mill the denture base and affix the artificial teeth.
1. Create the denture resin.

1. Mix the cold-cured resin powder and the liquid together well.
   After mixing, use a vibrator to extract the air bubbles.

2. Pour the mixture into the CA-DK2-FX (hereinafter referred to as the FX).

3. Wait for the surface of the mixture to dry.

4. Place the FX in the pressure pot.

5. Check the pressure pot’s water level.
   Adjust the amount of water if it is not at the level indicated on the pressure pot.
   

6. Set the pressure, temperature, and time on the pressure pot to polymerize the resin.
   Set the values that are required in order for the cold-cured resin being used to polymerize.

7. After polymerization, cool the resin at room temperature.

2. Mill the denture resin.

1. Remove the adapter cap.
   Use a torque screwdriver to loosen the adapter’s cap screws by turning them approximately four times each, and then remove the adapter cap.

2. Attach the adapter base to the FX.
   Align the edge of the adapter (A) with the edge of the FX (B).

3. Attach the adapter cap.

4. Tighten the cap screws (in four locations).
   Tighten the screws until this state is reached.
   Important
   To fix the part in place evenly, tighten the cap screws in order across the diagonals.

5. Mill the denture.
   Attach the FX to the machine, and then use the CAM data to mill the denture resin together with the FX.

3. Affix the artificial teeth.

1. Remove the adapter.
2. Use heat-resistant acrylic resin adhesive to affix the artificial teeth.

Removable Denture Workflow
Mill the tooth mold (the female mold for the artificial teeth), arrange the artificial teeth, polymerize the resin, and then mill the complete denture (full denture).
1. Affix the CA-DK2-FX and the CA-DK2-TR.

1. Apply heat-resistant acrylic resin adhesive to the CA-DK2-FX (hereinafter referred to as the FX).
   Measure approximately 0.5 ml of heat-resistant acrylic resin adhesive with an eye dropper, and then drip this adhesive onto one of the three locations indicated in the figure so this location has adhesive with a diameter of approximately 5 mm (0.20 in.). Repeat for the other two locations.
   Important
   • To prevent tray deformation, do not apply too much adhesive.
   • The surface on which adhesive is applied will have small air bubbles, but this is not a problem during milling.

2. Attach the CA-DK2-TR (hereinafter referred to as the TR) by aligning its recessed parts with the protrusions on the FX.

2. Mill the tooth mold (the female mold for the artificial teeth) into the TR.

1. Remove the adapter cap from the adapter.
   Use a torque screwdriver to loosen the adapter’s cap screws by turning them approximately four times each, and then remove the adapter cap.

2. Attach the adapter base to the FX.
   Align the edge of the adapter (A) with the edge of the FX (B).
   

3. Attach the adapter cap.

4. Tighten the cap screws (in four locations).
   Tighten the screws until this state is reached.
   Important
   To fix the part in place evenly, tighten the cap screws in order across the diagonals.

5. Mill the tooth mold (the female mold for the artificial teeth) into the TR.
   Attach the TR to the machine, and then use the CAM data to mill the tooth mold to use in fitting the TR with artificial teeth.
   

6. Loosen the cap screws, and then remove the adapter cap and the adapter from the FX.

3. Arrange the artificial teeth on the TR.

1. Apply one to two drops of heat-resistant acrylic resin adhesive to the TR’s tooth mold.

2. Check the shape of the tooth mold and the orientation of the artificial teeth.

3. Push the artificial teeth onto the TR’s tooth mold.
   

4. Check that the artificial teeth have been attached to the tooth mold without any gaps.
   Important
   The artificial teeth have an orientation that matches the tooth mold. Attach teeth with the proper orientation.

4. Create the denture resin.

1. Mix the cold-cured resin powder and the liquid together well.
   After mixing, use a vibrator to extract the air bubbles.

2. Pour the mixture into the FX where the artificial teeth have been set.

3. Wait for the surface of the mixture to dry.

4. Place the FX in the pressure pot.

5. Check the pressure pot’s water level.
   Adjust the amount of water if it is not at the level indicated on the pressure pot.
   

6. Set the pressure, temperature, and time on the pressure pot to polymerize the resin.
   Set the values that are required in order for the cold-cured resin being used to polymerize.

7. After polymerization, cool the resin at room temperature.

5. Mill the denture resin.

1. Attach the adapter base to the FX that has undergone polymerization.
   Align the edge of the adapter (A) with the edge of the FX (B) before attaching the base.

2. Attach the adapter cap.

3. Tighten the cap screws (in four locations).
   Tighten the screws until this state is reached.
   Important
   To fix the part in place evenly, tighten the cap screws in order across the diagonals.
   

4. Mill the complete denture (full denture).
   Attach the FX to the machine, and then use the CAM data to mill the denture resin together with the FX.
   

5. Loosen the cap screws, and then remove the adapter cap and the adapter from the FX.

Heat-cured resin

Denture Base Workflow
In this method, polymerize the resin, and then mill the denture base and affix the artificial teeth.
1. Drill a hole in the CA-DK2-FX.

1. Remove the adapter cap.
   Use a torque screwdriver to loosen the adapter’s cap screws by turning them approximately four times each, and then remove the adapter cap.

2. Attach the adapter base to the CA-DK2-FX (hereinafter referred to as the FX).
   Align the edge of the adapter (A) with the edge of the FX (B).
   

3. Attach the adapter cap.
   

4. Tighten the cap screws (in four locations).
   Tighten the screws until this state is reached.
   Important
   To fix the part in place evenly, tighten the cap screws in order across the diagonals.
   

5. Drill a hole in the FX.
   Attach the FX to the machine and cut off the part indicated in the figure.
   

6. Loosen the cap screws, and then remove the adapter cap and the adapter from the FX.

2. Create the denture resin.

1. Insert into the lidded container all the measured heat-cured resin liquid.
   

2. Insert 80% of the measured heat-cured resin powder so it fits below the liquid surface.
   

3. Insert the remaining 20% of the powder to cover the liquid surface.
   

4. Close the lid and mix the components together.

5. Wait 2 to 3 minutes until the mixture becomes porridge-like. If the room temperature is low, you may have to wait a little longer.

6. Fix the FX onto the protrusion in the silicone stand.
   Align the hole drilled in step 1. with the protrusion on the silicone stand.
   Supplemental
   Applying vegetable oil to the protrusion on the silicone stand makes it easier to remove the resin after polymerization.

7. Pour the mixture into the FX.
   Flatten the surface of the mixture with a spatula.
   

8. Cover the mixture with a piece of tissue paper.
   

9. Place a polyethylene sheet on the tissue paper.
   

10. Lightly press down on the polyethylene sheet and the tissue paper to absorb the liquid layer from the surface of the mixture.
    Important
    A liquid layer remaining on the surface may cause air bubbles to form there after polymerization.

11. Remove the polyethylene sheet and the tissue paper.

12. Place the silicone stand and the FX in the pressure pot.

13. Check the pressure pot’s water level and temperature.
    • Add water until approximately half the silicone stand is submerged.
    • Heat the water until its temperature is between 20°C and 30°C (68°F and 86°F).
    

14. Apply pressure for approximately 60 minutes.
    • After applying pressure, open the lid and check that there is no liquid on the resin surface.
    • This time is merely a guideline. Set the time required for the heat-cured resin being used to turn rubbery.

15. Perform the pre-polymerization.
    Gradually increase the water temperature to 65°C (149°F), and then perform pressurized and heated polymerization at 65 °C (149°F) for 90 to 120 minutes.
    Important
    The pre-polymerization time is merely a guideline. If cracks or air bubbles remain in the heat-cured resin being used, increase this time until there are no cracks or air
    bubbles.

16. Perform the polymerization.
    Perform pressurized and heated polymerization at 80°C (176°F) for 40 minutes.
    Important
    Heat-cured resin polymerizes at high temperatures. Handle it carefully after polymerization to avoid burns.

17. Remove the FX from the silicone stand, and then leave the FX at room temperature for approximately 30 minutes.

18. Cool the FX for approximately 15 minutes with cold water.

3. Mill the denture resin.

1. Remove the adapter cap.
   Use a torque screwdriver to loosen the adapter’s cap screws by turning them approximately four times each, and then remove the adapter cap.

2. Attach the adapter base to the FX that has undergone heated polymerization.
   Align the edge of the adapter (A) with the edge of the FX (B).
   

3. Attach the adapter cap.

4. Tighten the cap screws (in four locations).
   Tighten the screws until this state is reached.
   Important
   To fix the part in place evenly, tighten the cap screws in order across the diagonals.
   

5. Mill the denture base.
   Attach the FX to the machine, and then use the CAM data to mill the denture resin together with the FX.
   

4. Affix the artificial teeth.

1. Remove the adapter.
2. Use heat-resistant acrylic resin adhesive to affix the artificial teeth.

Removable Denture Workflow
Mill the tooth mold (the female mold for the artificial teeth), arrange the artificial teeth, polymerize the resin, and then mill the complete denture (full denture).
1. Affix the CA-DK2-FX and the CA-DK2-TR.

1. Apply heat-resistant acrylic resin adhesive to the CA-DK2-FX (hereinafter referred to as the FX).
   Measure approximately 0.5 ml of heat-resistant acrylic resin adhesive with an eye dropper, and then drip this adhesive onto one of the three locations indicated in the figure so this location has adhesive with a diameter of approximately 5 mm (0.20 in.). Repeat for the other two locations.
   Important
   • To prevent tray deformation, do not apply too much adhesive.
   • The surface on which adhesive is applied will have small air bubbles, but this is not a problem during milling.

2. Attach the CA-DK2-TR (hereinafter referred to as the TR) by aligning its recessed parts with the protrusions on the FX.

2. Drill holes in the FX and mill the tooth molds into the TR.

1. Remove the adapter cap.
   Use a torque screwdriver to loosen the adapter’s cap screws by turning them approximately four times each, and then remove the adapter cap.

2. Attach the adapter base to the FX.
   Align the edge of the adapter (A) with the edge of the FX (B).

3. Attach the adapter cap.

4. Tighten the cap screws (in four locations).
   Tighten the screws until this state is reached.
   Important
   To fix the part in place evenly, tighten the cap screws in order across the diagonals.
   

5. Drill holes in the FX and mill the tooth molds into the TR.
   Attach the FX and TR to the machine, and then use the CAM data to mill the tooth mold to use in fitting the TR with artificial teeth. Also drill holes in the FX.

6. Remove the FX and TR from the machine, loosen the cap screws, and then remove the adapter cap and the adapter from the FX.

3. Arrange the artificial teeth on the TR.

1. Apply one to two drops of acrylic resin adhesive to the TR’s tooth mold.

2. Check the shape of the tooth mold and the orientation of the artificial teeth.

3. Push the artificial teeth onto the TR’s tooth mold.

4. Check that the artificial teeth have been attached to the tooth mold without any gaps.
   Important
   The artificial teeth have an orientation that matches the tooth mold. Attach teeth with the proper orientation.

4. Create the denture resin.

1. Insert into the lidded container all the measured heat-cured resin liquid.
   

2. Insert 80% of the measured heat-cured resin powder so it fits below the liquid surface.
   

3. Insert the remaining 20% of the powder to cover the liquid surface.

4. Close the lid and mix the components together.

5. Wait 2 to 3 minutes until the mixture becomes porridge-like. If the room temperature is low, you may have to wait a little longer.

6. Fix the FX onto the protrusion in the silicone stand.
   Align the hole drilled in step 1. with the protrusion on the silicone stand.
   Supplemental
   Applying vegetable oil to the protrusion on the silicone stand makes it easier to remove the resin after polymerization.

7. Pour the mixture into the FX.
   Flatten the surface of the mixture with a spatula.
   

8. Cover the mixture with a piece of tissue paper.
   

9. Place a polyethylene sheet on the tissue paper.
   

10. Lightly press down on the polyethylene sheet and the tissue paper to absorb the liquid layer from the surface of the mixture.
    Important
    A liquid layer remaining on the surface may cause air bubbles to form there after polymerization.

11. Remove the polyethylene sheet and the tissue paper.

12. Place the silicone stand and the FX in the pressure pot.

13. Check the pressure pot’s water level and temperature.
    • Add water until approximately half the silicone stand is submerged.
    • Heat the water until its temperature is between 20°C and 30°C (68°F and 86°F).
    

14. Apply pressure for approximately 60 minutes.
    • After applying pressure, open the lid and check that there is no liquid on the resin surface.
    • This time is merely a guideline. Set the time required for the heat-cured resin being used to turn rubbery.

15. Perform the pre-polymerization.
    Gradually increase the water temperature to 65°C (149°F), and then perform pressurized and heated polymerization at 65
    °C (149°F) for 90 to 120 minutes.
    Important
    The pre-polymerization time is merely a guideline. If cracks or air bubbles remain in the heat-cured resin being used, increase this time until there are no cracks or air
    bubbles.

16. Perform the polymerization.
    Perform pressurized and heated polymerization at 80°C (176°F) for 40 minutes.
    Important
    Heat-cured resin polymerizes at high temperatures. Handle it carefully after polymerization to avoid burns.

17. Remove the FX from the silicone stand, and then leave the FX at room temperature for approximately 30 minutes.

18. Cool the FX for approximately 15 minutes with cold water.

5. Mill the denture resin.

1. Remove the adapter cap.
   Use a torque screwdriver to loosen the adapter’s cap screws by turning them approximately four times each, and then remove the adapter cap.

2. Attach the adapter base to the FX.
   Align the edge of the adapter (A) with the edge of the FX (B).

3. Attach the adapter cap.

4. Tighten the cap screws (in four locations) while pressing the FX in the direction indicated by the arrow.
   Tighten the screws until this state is reached. Important
   To fix the part in place evenly, tighten the cap screws in order across the diagonals.

5. Mill the complete denture (full denture).
   Attach the FX to the machine, and then use the CAM data to mill the denture resin together with the FX.
   

6. Loosen the cap screws, and then remove the adapter cap and the adapter from the FX.

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