Button versus buttonless castings for removable partial denture frameworks

Casting removable partial dentures (RPDs) without completely filling the sprue channels and generating casting buttons would result in saving metal and making more defect-free castings. This investigation tested whether a complete and sound RPD casting can be obtained when a minimal amount of metal is used. A factorial experimental design, three spruing methods, two metal feeding directions, and two different weights of metal were used to cast 60 Kennedy class II, modification 1 RPDs. The metal used to cast each framework was either enough to result in a full button or in no button. Visual and radiographic examinations and counting of defects were made by two independent operators who were unaware of the spruing method, feeding direction, or amount of metal used to make the framework. The completeness of the casting and the presence of porosities were evaluated for clasps, major connectors, and meshworks. The use of minimal metal to cast RPDs was equally as successful as using enough for a full button, provided that the appropriate spruing arrangement and metal feeding direction were chosen. Indirect metal feeding for maxillary RPDs was successful with the proper spruing arrangement.