International Journal of Dentistry Research 2025; 10(3): 123-125 DOI:10.31254/dentistry.2025.10310

Short Communication

Improving Wax Spacer Integrity and Removal in Custom Tray Fabrication Using Aluminium Foil

Shakeel S. Khazi¹ , Sesha M. Reddy² , Sherif A. Sadek^3,4 , Mohammed S.U.R Tippu⁵ , Ashwin L Narayanan⁶ , Mohammed Shammas⁷ , Tina S Titus⁸

Shakeel S. Khazi,Sesha M. Reddy,Sherif A. Sadek,Mohammed S.U.R Tippu,Ashwin L Narayanan,Mohammed Shammas,Tina S Titus

1. Lecturer/Specialist Prosthodontics, Department of Restorative Dentistry, College of Dentistry, Gulf Medical University, Ajman, United Arab Emirates
2. Assistant Professor, Department of Periodontics, City University, Ajman, United Arab Emirates
3. Associate Professor, Division of Prosthodontic, Department of Restorative, College of Dentistry, Gulf Medical University, Ajman, United Arab Emirates
4. Associate Professor, Department of Prosthodontic, Faculty of Dentistry, Cairo University, Cairo, Egypt
5. Lecturer/Specialist Oral and Maxillo Facial Surgeon, Department of Oral and Maxillo Facial Surgery, College of Dentistry, Gulf Medical University, Ajman, United Arab Emirates
6. Lecturer/Specialist Endodontics, Department of Restorative Dentistry, College of Dentistry, Gulf Medical University, Ajman, United Arab Emirates
7. Associate Professor, Division of Prosthodontics, Department of Oral and Maxillofacial Rehabilitation, Ibn Sina National College for Medical Studies, Jeddah, Saudi Arabia
8. Clinical Instructor, Department of Restorative Dentistry, Gulf Medical University, Ajman, United Arab Emirates

*Author to whom correspondence should be addressed.

Received: 17th November, 2025 / Revised: 1st January, 1970 / Accepted: 31st December, 2025 / Published : 17th January, 2026

Abstract

In the fabrication of complete dentures, a precisely made custom tray is essential for obtaining accurate impressions and for ensuring the correct application of pressure and relief on completely edentulous arches. The use of auto-polymerizing polymethyl methacrylate (PMMA) resin has simplified the process of custom tray fabrication. Light-activated polymerizing resin in combination with baseplate wax as a spacer remains a commonly used approach. However, the exothermic polymerization of PMMA can soften or melt the wax spacer, leading to dimensional distortion, tray contamination, and inconsistencies in spacer thickness, thereby compromising the tray’s intended function. This article presents a simple and effective technique that uses aluminium foil to maintain the intended wax spacer thickness and facilitate its easy removal during custom tray fabrication with auto- and light-activated resin materials.