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

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Processing instructions

Everest ZS-Blank

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1 User instructions

1.1 User guide

1.1.1 Abbreviations

Abbre‐

viation Explanation GA Instructions for use PA Care instructions REC Assembly instructions TA Technician's instructions STK Safety checks

IEC International Electrotechnical Commission RA Repair instructions

EMC Electro magnetic compatibility VA 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.

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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

indicates the maximum hazard level. indicates a directly hazardous situation that can cause death or serious injury.

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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-sta‐} bilised zirconium oxide. They are easy to process in this soft state, and are fabri‐ cated larger in the KaVo Everest®_{engine to compensate for the individually-calcu‐} lated 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 * 106_K-1

Flexural strength 1200 MPa

Elasticity modulus 210 GPa Fracture toughness 8 MN/m3/2 Chemical solubility 10 μg/cm3 Thermal conductivity 2.5 W/ mK

Material numbers for KaVo Everest

®

_ZS

Mat. no. 1.002.9555, 16x16 (DxH), ZS(16)

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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 mm2 ▪ 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 zir‐ conium 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 regula‐ tions.

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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 gar‐ bage while observing local regulations (waste code: 200301).

▶ If permitted by regulations, the packaging can be recycled (used paper, card‐ board) or disposed with household garbage.

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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. Ob‐ serve 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.}

Note

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 mm2

– 4-member: min. 12 mm2

– more than 4-member: min. 16 mm2

▪ 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

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▪ The shape 1 is not suitable for manufacturing with the round blank.

4.2 KaVo Everest

®

_{ZS blanks}

Note

Check the concentration, purity and level of the cooling lubricant weekly (see the instructions for use of the combination and base test).

Note

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

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.

Note

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.

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Note

The Universal Inplast must be mixed well. The homogeneity of the plastic can oth‐ erwise 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 posi‐ tioning appliance from the insert.

Note

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.

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▶ 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.

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.

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▶ 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 com‐ pressed 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.

Note

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.

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CAUTION Hot, liquid wax Burns

▶ Be particularly cautious when working with hot, liquid wax.

Note

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.

▶ 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.

or

▶ 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).

or

▶ 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.

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▶ 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 Ever‐ est®_{therm. The radiation heat of the ceramic oven can be exploited.}

Note

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▶ 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.

Note

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 pro‐ duction 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 zir‐ conium 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).

Note

The electricity and compressed air supply must be ensured for night operation.

4.3 KaVo Everest

®

_{ZS round blank}

Note

Check the concentration, purity and level of the cooling lubricant weekly (see the instructions for use of the combination and base test).

Note

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

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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)

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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

Note

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.

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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.

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4.3.3 Cutting the ZS restoration

▶ The restorations can be carefully cut from the round blank using a suitable car‐ bide 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

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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

Note

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.

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▶ 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.

Note

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 HeatMinute Heat°C/minute ca.temperature HoldMinute VACMinute

500 - 5.00 as low as pos‐

sible 1000 15.00

-(source: Vita firing table for Vita VM9).

4.4.2 Veneering ZS frameworks

Note

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

Note

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.

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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

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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

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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.

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