Processing instructions Everest ZS-Blank. Always be on the safe side.

Processing instructions Everest ZS-Blank Always be on the safe side.

Distributed by: KaVo Dental GmbH Bismarckring 39 D-88400 Biberach Tel. +49 7351 56-0 Fax +49 7351 56-1488 Manufacturer: Kaltenbach & Voigt GmbH Bismarckring 39 D-88400 Biberach www.kavo.com

Table of contents Table of contents Table of contents 1 1 User instructions 2 1.1 User guide 2 1.1.1 Abbreviations 2 1.1.2 Symbols 2 1.1.3 Target group 2 2 Safety 3 2.1 Description of safety instructions 3 2.1.1 Warning symbol 3 2.1.2 Structure 3 2.1.3 Description of danger levels 3 3 Information on materials 4 4 Processing 7 4.1 Preparing and planning the model 7 4.1.1 Preparing the model 7 4.1.2 Planning the model 7 4.2 KaVo Everest ZS blanks 8 4.2.1 Embedding ZS blanks 8 4.2.2 Inserting the insert into the KaVo Everest engine 9 4.2.3 Backfilling the ZS restoration 10 4.2.4 Removing the ZS piece from the bed/sintering process 12 4.3 KaVo Everest ZS round blank 14 4.3.1 Insert the ZS circular blank into the KaVo Everest engine 15 4.3.2 Round blank management 16 4.3.3 Cutting the ZS restoration 18 4.3.4 Sintering round blank restorations 18 4.4 Final tasks 19 4.4.1 Finishing the ZS piece 19 4.4.2 Veneering ZS frameworks 20 4.4.3 Incorporating the ZS piece 20 5 Identification plates 21 1/23

1 User instructions 1.1 User guide 1 User instructions 1.1 User guide 1.1.1 Abbreviations Abbreviation GA PA REC TA STK IEC RA EMC VA Explanation Instructions for use Care instructions Assembly instructions Technician's instructions Safety checks International Electrotechnical Commission Repair instructions Electro magnetic compatibility Processing instructions 1.1.2 Symbols See the section Safety/Warning Symbols Important information for users and technicians CE mark (Communauté Européenne). A product with this mark meets the requirements of the applicable EU directive. Action required 1.1.3 Target group This document is for dental technicians and laboratory personnel. 2/23

2 Safety 2.1 Description of safety instructions 2 Safety 2.1 Description of safety instructions 2.1.1 Warning symbol Warning symbol 2.1.2 Structure DANGER The introduction describes the type and source of the danger. This section portrays the possible consequences of non-observance. The optional step covers necessary measures for avoiding hazards. 2.1.3 Description of danger levels Safety instructions with three hazard levels are used in this document for avoiding personal and property damage. CAUTION CAUTION indicates a hazardous situation that can cause damage to property, or mild or moderate physical harm. WARNING WARNING indicates a hazardous situation that can cause death or serious injury. DANGER DANGER indicates the maximum hazard level. indicates a directly hazardous situation that can cause death or serious injury. 3/23

3 Information on materials 3 Information on materials Zirconium dioxide as defined by materials science Zirconium dioxide is a high-performance, oxide ceramic. It is often called ceramic steel since it is extremely strong. The aesthetics of its translucence in thin walls are excellent, and it can also be stained in various colours. The biocompatibility of zirconium oxide is also excellent and has therefore been used for implants for years in addition to dentistry. In addition, its elasticity modulus is high, and resists breaking. This quality is achieved by doping with yittrium oxide. When external energy is applied, for example in a crack, the volume of the material increases at this site at room temperature in a stabile phase. The arising pressure counteracts the crack and prevents it from spreading and the ceramic from failing. The transformation is the basis of the high strength, the impressive toughness and excellent long-term stability. Zirconium oxide pieces made using CAD/CAM also have the following advantages: Corrosion resistance Very fine particle size No glass phase as the particle binder Extreme high density Porosity-free Conventional incorporation Adhesive or non-adhesive KaVo Everest ZS blanks and ZS round blanks consist of presintered, yittrium-stabilised zirconium oxide. They are easy to process in this soft state, and are fabricated larger in the KaVo Everest engine to compensate for the individually-calculated shrinkage factor, and then they are sintered to achieve full density in a special high-temperature oven, the Kavo Everest Therm. They shrink to form a very strong, precisely fitting framework. Technical data on the KaVo Everest ZS CTE (25 C to 500 C) 10.0 * 10 6 K -1 Flexural strength 1200 MPa Elasticity modulus 210 GPa Fracture toughness 8 MN/m 3/2 Chemical solubility 10 μg/cm 3 Thermal conductivity 2.5 W/ mk Material numbers for KaVo Everest ZS Mat. no. 1.002.9555, 16x16 (DxH), ZS(16) Mat. no. 1.002.7337, 20x20 (DxH), ZS(20) Mat. no. 1.002.0468, 42x20x16 (LxWxH), ZS(42/16) Mat. no. 1.002.7335, 42x20x20 (LxWxH), ZS(42/20) 4/23

3 Information on materials Mat. no. 1.002.7336, 60x25x20 (LxWxH), ZS(60/20) Mat. no. 1.005.3309, 100x16 (DxH), ZS(100x16) Mat. no. 1.005.3310, 100x20 (DxH), ZS(100x20) Mat. no. 1.005.3311, 100x25 (DxH), ZS(100x25) Indications for the KaVo Everest ZS Crown frameworks in the anterior and posterior areas Bridge frameworks in the anterior and posterior areas Primary conical crowns and telescopic crowns Inlay frameworks Implant abutments based on the Neolink for KaVo (Neoss) in the anterior and premolar regions Contraindications for the KaVo Everest ZS insufficient oral hygiene bruxism tangential preparations unsatisfactory preparation results post and cores unveneered crowns, inlays, onlays and bridges when there are more than two pontics when the bar cross-section is less than 12 mm 2 Implant abutments without Neolink (Neoss) Implant abutments in the molar region Cantilevered bridges Attachments It is the responsibility of the dentist to determine whether to use customized products such as long mandibular bridges. The crown and bridge frameworks made of Everest ZS blanks and ZS round blanks can be individually veneered with the veneer ceramic developed especially for zirconium dioxide. Preparation basics The preparation can be made either with a 90 hollow neck, or a shoulder with rounded inner edge. Try to achieve a circular preparation depth of 1 mm. All transitions from the axial to the occlusal or incisal surfaces are to be rounded off with a radius of 1 mm. Optionally, a radius correction can be made in the surface module of the construction software. See also: KaVo Everest preparation conditions Transportation and storage The ZS material is nonhazardous as defined by national and international regulations. 5/23

3 Information on materials Transportation/storage temperature -25 C to +80 C Humidity 5% to 95% Store KaVo Everest ZS blanks and ZS round round blanks in a clean and dry place at room temperature. Store the blanks in the original packaging at room temperature (20 C). Disposal Everest ZS blanks and ZS round blanks can be disposed with household garbage while observing local regulations (waste code: 200301). If permitted by regulations, the packaging can be recycled (used paper, cardboard) or disposed with household garbage. 6/23

4 Processing 4.1 Preparing and planning the model 4 Processing 4.1 Preparing and planning the model 4.1.1 Preparing the model Apply the criteria of conventional casting when preparing the model and dies. Observe care in preparation to ensure a precise fit later. All model segments must be designed to be removable. They must easily release from the base to prevent a blur when later removing the individual stumps in the scanner. A conventional plaster base is recommended. Do not use white or reflective plates since they can negatively influence measurement. It is essential to use Everest Rock (100 g: 20 ml) to manufacture the dental arch. Other plasters can impair measurement. The preparation margin should be exposed at a 90 angle. Sharp angles can cause a loss of data at these sites. Do not mark the preparation margin. Waxing in and rounding sharp-edged preparations ensures an easier fit. This can be done with Everest Scan Wax or a light-hardening opaque plastic. The stumps may not be treated before scanning. Do not use stump varnish, die spacer or hardener. The model preparation method for working with the Neolink can be found in the instructions for use of the KaVo Everest Energy CAD software. 4.1.2 Planning the model For a safe construction, do not undershoot the following CAD parameters: Metal margin A = 0.3 Framework thickness B = 0.55 The minimum cross-section of the bars depends on the span of the bridge: 3-member: min. 9 mm 2 4-member: min. 12 mm 2 more than 4-member: min. 16 mm 2 To ensure safe work, the transitional area X = 0.5 may not be larger. The shape of the bars has a direct influence on the stability of the work. A round or oval cross-section provides better static reinforcement than a square one The height of the bar is more important than its width 7/23

4 Processing 4.2 KaVo Everest ZS blanks The shape 1 is not suitable for manufacturing with the round blank. 4.2 KaVo Everest ZS blanks Check the concentration, purity and level of the cooling lubricant weekly (see the instructions for use of the combination and base test). To ensure sufficient fixing, change the setscrews in the gripping yokes and tools every four months. Use the following ZS burrs for shaping: KaVo Everest Milling Pin ZS 3 (3 mm dia.) Mat. no. 1.002.8028 KaVo Everest Milling Pin ZS 1 (1 mm dia.) Mat. no. 1.002.8027 4.2.1 Embedding ZS blanks The ZS blanks should only be embedded when necessary. While embedding, the Everest label must be on top so that it can be read. Do not embed them in advance. Avoid covering the Everest label with Universal Inplast while embedding. For Universal Inplast, always mix components A and B at a precise weight ratio of 1:1. Shake container a well before use. The Universal Inplast components must be mixed very well for approximately 45-60 seconds. 8/23

4 Processing 4.2 KaVo Everest ZS blanks The Universal Inplast must be mixed well. The homogeneity of the plastic can otherwise be uneven and the plastic may not cure evenly. This can cause the blank to loosen and may generate problems with milling. Choose a ZS positioning appliance appropriate for the blank size. Insulate the ZS positioning appliance well with Vaseline. Then place the insert on the positioning appliance, and also tighten the thumb screws. Make sure the insert is precisely seated. When using the silicone positioning tool: Use Vaseline to close the holes in bridge inserts. Do not use Vaseline to insulate the inside of the insert. With bridges, fill the insert with Universal Inplast up to the top edge of the blank. In the case of crown bridges, fill the insert with Universal Inplast up to the top edge of the insert. Once the Everest Universal Inplast is completely hardened, remove the positioning appliance from the insert. Do not forcefully break it out since this may damage the blank. 4.2.2 Inserting the insert into the KaVo Everest engine Affix the insert at the desired location on the yoke, and affix the setscrews in the front of the gripping yoke. Then select the provided job and assign it to the corresponding production site. The "Define blank" dialog opens. 9/23

4 Processing 4.2 KaVo Everest ZS blanks To determine the shrinkage factor and the LOT number, the ID Reader must be held on the middle of the label of the blank. The Everest Label must be removed before production. Fix the insert in the KaVo Everest gripping yoke at the provided place. Start the milling program. See also: Instructions for use for the KaVo Everest engine (Mat. no. 1.002.3165) Instructions for use for the KaVo Everest engine Base Camp 4140 (Mat. no. 1.005.4467) 4.2.3 Backfilling the ZS restoration After grinding the cavity, the program automatically stops so that the inside can be filled. Do not remove the gripping yoke or insert from the engine. 10/23

4 Processing 4.2 KaVo Everest ZS blanks The cooling lubricant and grinding residue must be rinsed out well with water. Preferably use a spray bottle. Then gently dry the cavity with oil-free compressed air. Make sure that the compressed air does not enter the spindle. Heat the cavity well and evenly to about 45 C for at least one minute/unit at a distance of 15-20 cm. A hairdryer works best. A hair drier with max. 1,600 Watt output is recommendable for gentle heating. Properly heating is essential for successful production. Do not use a hot hair drier for heating. 11/23

4 Processing 4.2 KaVo Everest ZS blanks CAUTION Hot, liquid wax Burns Be particularly cautious when working with hot, liquid wax. The Inwax should not be heated in the working area since it becomes excessively soiled and the Inwax cannot be heated in a controlled manner. or or It is best to heat the Everest Inwax in a fire-proof container (such as a new ceramic pickling bowl) to a max. 100 C. You can alternately use a chocolate heater (for example by Unhold). The ideal wax temperature is reached at level 2. The wax tends to separate, so it needs to be stirred well. Fill the preheated cavity. Pour in the wax up to the upper edge of the insert and overfill it just a bit. After the Inwax fully hardens, close the door of the Everest engine. Continue the program (see the screen). The Autostart function can alternatively be used. Select the time period after which the program is automatically continued. Set to at least 15 minutes for crowns and copings, and set to 20 to 40 minutes for bridges depending on the size. Abutments Items delivered with the "Neoss for KaVo" abutments: Designation Figure Description Abutment screw Material: Gold or titanium 1: Long thread 2: Chamfered screw tip Laboratory screw Material: Titanium 1: Short thread 2: Sharp-edged screw tip See also: Instructions concerning abutments by Neoss or www.neoss.com 4.2.4 Removing the ZS piece from the bed/sintering process After grinding, remove the insert with the finished casting from the gripping yoke. 12/23

4 Processing 4.2 KaVo Everest ZS blanks Use a hot wax knife to carefully and generously cut the casting from the insert, or place it in the preheating oven with the insert. Do not heat the casting with a hot air blower since it can cause heat cracks. CAUTION Hot preheating oven Burning hazard! Be particularly cautious when working with the preheating oven. To remove remaining wax, place the workpiece on a paper towel or muffle cloth in the preheating at a max. 100 C. Make sure that the oven is clean. Do not remove the casting from the preheating oven with a metal object (such as tweezers). Always avoid sudden temperature changes since they can generate cracks. Since zirconium oxide is very sensitive in the presintered state and cracks can form, do not work on it in this state. In addition, other materials such as from smoothing with a rubber wheel can be fired into the crown. For information on staining, consult the processing instructions of the respective manufacturer. Never dip the ZS piece into the stain when hot. The stained restoration must be thoroughly dry before starting the KaVo Everest therm. The radiation heat of the ceramic oven can be exploited. Cracks in the ZS material after sintering can arise from thermal stress and residual moisture before sintering. The sand must be completely sintered before it is used. 13/23

4 Processing 4.3 KaVo Everest ZS round blank To sinter the framework, place its occlusal side in the dish filled with sintering sand. Make sure that the framework parts are properly supported to prevent distortion during sintering. The framework should lie evenly and loosely in the sand. It may not be buried in the sand. The provided amount of sintering sand is enough for 3 units. The production should be protected from contamination up to sintering. Even minute metal particles in the sintering oven on the framework or in the sand can cause the zirconium to discolour green. ZS and HPC may not be sintered in the same sintering dish. Place the ceramic dish with the cut, de-waxed casting at room temperature in the KaVo Everest therm. Start the program. See also: Instructions for use for the KaVo Everest engine therm (Mat. no. 1.002.8845). The electricity and compressed air supply must be ensured for night operation. 4.3 KaVo Everest ZS round blank Check the concentration, purity and level of the cooling lubricant weekly (see the instructions for use of the combination and base test). To ensure sufficient fixing, change the setscrews in the tools every four months (Mat. no. 1.004.6876). Use the following ZS burrs to machine round blanks: KaVo Everest Milling Pin ZS 1 long (1 mm dia.) Mat. no. 1.004.8063 KaVo Everest Milling Pin ZS 3 (3 mm dia.) Mat. no. 1.004.8064 14/23

4 Processing 4.3 KaVo Everest ZS round blank 4.3.1 Insert the ZS circular blank into the KaVo Everest engine Place the round blank in the provided place on the KaVo Everest yoke. Use an appropriate clamping ring: ZS 100 x 16/25 or ZS 100 x 20. Place the clamping ring on the round blank. The groove in the round blank must be aligned with the pin in the yoke. Evenly tighten the hexagon socket screws. Make sure that the clamps lie on the edge of the clamping ring. Assign jobs. See also: Instructions for use for the KaVo Everest engine (Mat. no. 1.002.3165) See also: Instructions for use for the KaVo Everest engine Base Camp 4140 (Mat. no. 1.005.4467) After the fitting side is produced, the yoke automatically turns over and the occlusion starts to be milled. 15/23

4 Processing 4.3 KaVo Everest ZS round blank 4.3.2 Round blank management Positioning the restorations Sufficient ZS material must be between the individual units so that the round blank remains stable and the restorations do not break out. Minor overlaps of the individual restorations may occur, but not of the bars. Define bars No bars may be deleted from any of the ZS pieces. The bars may be cut depending on the size of the piece. The bars must be positioned at a right angle to the framework. Coping Leave all 4 bars in an activated state (blue). Bridges 2 to 4 elements Leave 2 bars in an activated state (blue) on each of the terminal members. The remaining bars of pontics can be cut (green) or reduced (brown). The bars of stumps (teeth) may not be cut. Leave them in an activated state or reduce them. 16/23

4 Processing 4.3 KaVo Everest ZS round blank Bridges 5 to 6 elements: Leave 2 bars in an activated state (blue) on each of the terminal members and the middle members. The remaining bars of pontics can be cut (green) or reduced (brown). The bars of stumps (teeth) may not be cut. Leave them in an activated state or reduce them. Setting pins Pins can be generated to provide sufficient retention and prevent distortion when sintering large pieces on the sintering plate. No pins may be set on the copings. Pins may be created on bridges depending on their size and geometry. If pins are created, put a pin on each unit. The pins must be offset, i.e., not in a line, to ensure that they provide reliable retention. Pins may not be place on the outer margin of the geometry. 17/23

4 Processing 4.3 KaVo Everest ZS round blank 4.3.3 Cutting the ZS restoration The restorations can be carefully cut from the round blank using a suitable carbide cutter. Pay special attention to the edges of the restorations. 2 to 4 element bridges: 2-4 member bridges should be completely cut out of the material before being sintered. 5 to 6 element bridges: To prevent delays, the bridges can be sintered with the remaining round blank material. Leave bars on the lingual side of terminal copings and cut the other bars. The distance from the cut bars to the remaining material should be 1 mm. 4.3.4 Sintering round blank restorations Before sintering, the Everest chip must be removed from the round blank. Sintering bridges without residual round blank material Follow the instructions and descriptions for the sintering process. See also: 4.2.4 Removing the ZS piece from the bed/sintering process, Page 12 18/23

4 Processing 4.4 Final tasks Sintering bridges with residual round blank material Use a sintering plate Place the ZS bridge on the pins, and sinter using the ZS round blank program. Cutting out the sintered ZS pieces from residual round blank material CAUTION Irritating dust when cutting out the sintered ZS piece Irritation of the eyes and mucosa! Grinding dust must not be inhaled. A dust mask and protective glasses are required. Cut the ZS piece from the residual round blank material while cooling with water and with the help of a turbine. Do not apply pressure, and use new diamond coated tools. 4.4 Final tasks 4.4.1 Finishing the ZS piece The entire framework does not have to be reworked as is the case with metal frameworks. CAUTION Hot preheating oven Burning hazard! Be particularly cautious when working with the preheating oven. CAUTION Chips and irritating dust from finishing the polymers Irritation of the eyes and mucosa! Polymers must be worked on with a local dust extraction system. Make sure the milling dust does not get in the eyes. Avoid contact with mucous membranes. Grinding dust must not be inhaled. A dust mask and protective glasses are required. Do not eat or drink while working. After sintering, the ceramic bowl can be removed from the oven at 300 C. Remove the piece from the bowl when it is warm to the touch. Do not cool with compressed air. This can cause cracks. Do not inhale the zirconium sand. If needed, the cavity can be blasted with aluminium oxide 50 μm. 19/23

4 Processing 4.4 Final tasks Observe the additional instructions of the manufacturer of the utilised fastening material. If you need to refine a sintered ZS piece, use water cooling and a turbine. Do not apply pressure, and use tools with new diamonds. Avoid sparks. Do not blast the surfaces to be veneered - it is not necessary. However, preheating before veneering as instructed by Vita is recommended to relieve stress in the material and degrease the surface. Vt. C Hold Minute Heat Minute Heat C/minute 500-5.00 as low as possible ca. Hold VAC temperature Minute Minute 1000 15.00 - (source: Vita firing table for Vita VM9). 4.4.2 Veneering ZS frameworks ZS frameworks must be veneered. The surfaces to be veneered do not have to be blasted. The remaining veneer procedure can be found in the processing instructions of the respective veneer ceramic manufacturer. 4.4.3 Incorporating the ZS piece Provisional cementing is highly inadvisable. Before the framework is inserted in a patient s mouth, it needs to be sufficiently cleaned and disinfected. The framework is permanently inserted using the usual fastening materials for adhesive and non-adhesive fastening. Additional information can be obtained from the preparation guide. 20/23

5 Identification plates 5 Identification plates ZS blanks Material number Abbreviation of the dimension 1.002.9555 16 1.002.7337 20 1.002.0468 B 42/16 1.002.7335 B 42/20 1.002.7336 B 60/20 Type Everest ZS blank (X) Material, (dimension in mm) Quantity REF Reference number or material number CE mark according to EC Directive 93/42 for medical devices Batch ID Date of manufacture Year - month Reference to maximum use (Same as "Can be used until...") Year - month Observe processing instructions 21/23

5 Identification plates ZS circular blank Type Everest ZS round blank (X) Material, (dimension in mm) Quantity REF Reference number or material number CE mark according to EC Directive 93/42 for medical devices Batch ID Date of manufacture Year - month Reference to maximum use (Same as "Can be used until...") Year - month Observe processing instructions Material number Dimension 1.005.3309 dia. 100 x 16 1.005.3310 dia. 100 x 20 1.005.3311 dia. 100 x 25 Storage and transport 22/23

5 Identification plates Air pressure range 700 hpa to 1060 hpa Humidity range 5% to 95% Temperature range -25 C to +80 C Permissible stacking load 10 Kg Fragile - protect against impact. Protect from moisture. Protect from radiation and sunlight. 23/23

1.002.9040 kb 20091016-02 en