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WORK INSTRUCTION

MOULD PRODUCTION
UV TECHNOLOGY ITE PRODUCTION

S E R V I CE & P R O D U C T I O N S U P P O RT

BERNAFON AG

SWITZERLAND

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MOULD PRODUCTION

History
Date

2015-09-22

Rev. no

1.0

Comments

Page 9: Section Common guidelines to Gel mould production, comment for protruding parts updated.
Pages 11-15: Sections Impression preparation for gel mould: CIC/MIC; ITC Half Shell; ITE Half Shell; ITE Full Shell,
photos from modelling added.
Page 18: Information how many times gel can be re-used added.

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MOULD PRODUCTION

Table of contents
History ................................................................................................................................. Page 2
Common materials for Mould production ............................................................................... Page 4
Control mould production ..................................................................................................... Page 5
Common guidelines to Gel mould production ..................................................................... Page 9
Impression preparation for gel mould: CIC/MC ...................................................................... Page 11
Impression preparation for gel mould: ITC Half Shell .............................................................. Page 13
Impression preparation for gel mould: ITE Half Shell .............................................................. Page 14
Impression preparation for gel mould: ITE Full Shell .............................................................. Page 15
After trimming ...................................................................................................................... Page 17
Waxing of impression and gel mould production.................................................................... Page 18

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MOULD PRODUCTION

Common materials for Mould production


Description

Code No

Cutting plate

838-03-025-02

Knife, Stanley

825-20-100-00

Blades, Stanley (10 pcs.)

890-04-027-05

Miller, cylindrical 6.0 mm

890-20-067-08

Sandpaper, grit 180, width 15 mm, green

890-20-154-04

Holder for sandpaper

890-21-317-02

Wax knife (110V)

804-24-005-00

Wax knife (220V)

804-24-015-02

Correction wax, red (60 gr.)

788-01-120-07

Dipping wax, purple (500 gr.)

788-01-023-09

Form, large (4 pcs.)

890-21-376-04

Form, small

890-21-680-03

Gel fotogel (6 kg.)

792-10-040-07

Tweezers, angled

890-21-082-09

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MOULD PRODUCTION

Control mould production

Other styles
7 mm
CIC/MIC
12 mm

Ear line

1. The impression must be evaluated at the log-in step,

2. The impression must be:

before control mould production to ensure the best results.

Fully casted.

Compare impression with a. Requested instrument,

With the necessary style-canal length which is minimum

b. Req. style (enough space?)

12 mm for CIC and 7 mm for all other styles.


The ear line must be visible.

You can nd this infomation in the Work Order.

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Remove

Only excess of material

3. Remove sponge or cotton wool from the canal tip.

4. Cut excess of material at the base of the impression and


make it at.

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MOULD PRODUCTION

Only excess of material

Order number

5. Cut only excess of material around the impression

6. Write order number on the impression (the same number

(concha side). Be careful not to cut too much on the Tragus

as on the Work Order).

side.

Perforated spoon
Wax, purple

Wax temperature
Down
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We recommend using the


purple dipping wax melted
at the temperature of
85-120 C

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Relevant imperfection
corrected

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7. Fill up relevant lack of material (imperfection) on the

8. Place the impression on the perforated spoon. Deep the

impression using correction wax and the wax knife.

impression into the wax purple in one continuous and calm


movement. The impression must be lifted up just after it is
fully covered with wax.

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No excess of wax

9. After impression dipping, check that there is not excess of

10. Place the impression at the centre of the form.

wax on the points shown in the picture.

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MOULD PRODUCTION

11. Fill the form with duplicating silicone Duglasil CFS, clear,

12. Place an identication label (order number) in the

using the silicone mixing machine. If you do not have the

silicone.

machine, mix the silicone in the ratio of 1:1 by stirring the


material in a cup and pour it in the form with the impression.

Impression covered
with silicone

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13. Check that the control mould has no air bobbles (or

14. Let the silicone harden at room temperature

as few as possible) and that the impression is completely

(approx. 20 C) for 5 minutes.

covered with silicone material.

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Loose and
remove

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Angled tweezer

Angled tweezer

Angled tweezer

Compressed air

15. When hardened remove the control mould from the form

16. a. Remove carefully impression from the control mould

by loosing it from the inside of the form.

using an angled tweezers. b. Remove wax from control


mould using compressed air.

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MOULD PRODUCTION

Open canal tip

Same number as
Work Order

17. Cut excess of material on the control mould, on the

18. Check that the order number on the impression and in

concha side. Open the canal tip side of the control mould

the control mould is the same as on the Work Order.

being careful not to cut the canal length.

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MOULD PRODUCTION

Common guidelines to Gel mould production

Area visible
outside the ear
2886

2886
Ear line

1. The number on the impression must correspond to the

2. The area under the ear line correspond to the part of the

one on the order form and control mould.

instrument that will be visible outside the ear, therefore it


has to be trimmed as carefully as possible.

Canal end
for ITE

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Do not trim

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Part that locks


instrument in the ear

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3. Remember never to trim the part of the ear canal which

4. Verify canal direction related also to style.

locks the instrument tight in the ear.

Correction
wax

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Trimmed area

5. If the canal end has protruding parts, then there is a need

6. If there is a big lack of material, ask for new impression or

to trim it as it is shown on the photo. Dont remove all

if this is not possible, correct the part missing material with

material from protruding parts. Leave small bump. It is

correction wax, following the canal end direction.

needed to keep instruments in the canal.

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MOULD PRODUCTION

No excess of wax

Wax knife

7. Use wax knife at the temperature of 200-220 C.

8. Be careful not to overbuild the impression with wax.


Remember: excess of wax on impression cause a thick,
hurting shell in the control ear.

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9. Use form.

10. The gel mould, after its purpose, can be re-used


2-4 times more beginning from the melting process
(see page 15, step 3 for more information).

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MOULD PRODUCTION

Impression preparation for gel mould: CIC/MC


Base of
impression
Cymba-Concha

Concha

Knife,
Stanley

1. Cut the base of the impression.

2. Cut the Concha straight through, where the Cymba-Concha


starts.
Excess of
material

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Concha

S E R V I C E & P R O D U C T I O N S U P P O RT

3. Position the impression as shown in the picture and cut

4. Cut the Concha further if necessary and eliminate excess

the concha in the CIC angle.

of material.
2nd bend

2nd bend

1st bend

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2nd bend

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1st bend

5. The impression for the CIC must have the rst and second

CIC placement in the ear.

bend. Cut the canal end tip just after the second bend.
If only the rst bent is present, cut as little as possible
keeping in mind the canal direction.

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MOULD PRODUCTION

Impression preparation for gel mould: CIC/MC


Miller
cylindrical

6. Trim to eliminate excess of material.

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MOULD PRODUCTION

Impression preparation for gel mould: ITC Half Shell


Base of
impression
Cymba-Concha

Concha

Knife,
Stanley

2. Cut the Concha straight through, where the Cymba-Concha

1. Cut the base of the impression.

starts.

2nd bend

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3. Position the impression as shown in the picture. Cut the

4. Verify canal direction related also to style.

Concha in the ITC/ITE angle (90) and excess of material if


necessary.

Miller
cylindrical

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5. Trim to eliminate excess of material.

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ITC HS placement in the ear.

U V T EC H N O LO GY

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MOULD PRODUCTION

Impression preparation for gel mould: ITE Half Shell


Base of
impression
Cymba-Concha

Concha

Knife,
Stanley

1. Cut the base of the impression

2. Cut the Concha straight through, where the Cymba-Concha


starts.

Cut excess of material


Cut

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Cut

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3. Position the impr. as shown in the picture and cut the

4. Cut the canal end tip just after the rst bend keeping in

Concha in the ITE Half Concha side angle (90) and excess

mind the canal direction.

of material if necessary.

Miller
cylindrical

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5. Trim to eliminate excess of material.

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ITE HS placement in the ear.

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MOULD PRODUCTION

Impression preparation for gel mould: ITE Full Shell


Ear line

Cut
parallel

Locking points
Locking
points
Knife,
Stanley

1. Mark locking points on the impression.

2. Cut the base of the impression parallel to the ear line


being careful not to go under it (the locking points must be
visible).

Cutting line

Cymba-concha

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3. Find the cutting line on the Cymba-Concha using control

4. Cut excess of Cymba-Concha and excess of material,

ear.

if necessary.

Cutting line

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1st bend

5. Cut the canal end tip just after the rst bend keeping in

FS placement in the ear.

mind the canal direction.

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MOULD PRODUCTION

Impression preparation for gel mould: ITE Full Shell


Miller
cylindrical

6. Trim to eliminate excess of material.

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MOULD PRODUCTION

After trimming
Canal end
direction OK!
Fitting OK!

1. After trimming check for: Correct canal end direction in

2. Correct tting (no gap or pressure points) in the control

the control mould.

mould.

Locked in
the control mould

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Cut angle OK!

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3. Correct base cut/angle (Concha cut) in the control mould.


For full concha check that the base locks rmly the impression.

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MOULD PRODUCTION

Waxing of impression and gel mould production


Perforated spoon
Wax, purple

Wax temperature
Down
We recommend using the
purple dipping wax melted
at the temperature of
85-120 C

1. Place the trimmed-to-style impression on the perforated

2. Place the impression at the centre of the form.

spoon. Deep the impression into the wax purple in one


continuous and calm movement. The impression must be
lifted up just after it is fully covered with wax.

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Temperature controled
gel machine

3. Prepare the gel (Fotogel): a. Melt it at the temperature

4. Fill the form with gel. Avoid air bobbles by starting from

of 92 C. b. Decrease temperature until 44-47 C. For this

the bottom-side of the form and lling up around the

process, use the temperature controlled gel machine.

impression.

Note: Gel mould can be re-used 2-4 times.

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MOULD PRODUCTION

Fill up if use of
ALC machine*

*) Automatic Light Curing


5. a. Remove air bobbles. b. Place an identication label

6. Let the gel mould harden: At room temp. (approx. 20 C)

(order number) in the gel. Note: Fill form up with gel if

for approx. 30-40 minutes or in the refrigerator for approx.

casting shell with ALC machine.

20 min.

Loose and
remove
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Angled tweezer

Compressed air

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7. When hardened remove the gel mould from the form by

8. a. Remove carefully impression from the gel mould using

loosing it from the inside of the form.

an angled tweezers. b. Remove wax from gel mould and dry


it using compressed air.

Cut only excess

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9. Cut excess of material on the gel mould, on the Concha


siden (if necessary).

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