Method for fabricating odontoforms and dental restorations having infused ceramic network

A process for producing a ceramic network material from a ceramic suspension, wherein said suspension includes dispersed ceramic particles in a medium containing water and a dispersant, comprising the steps of:

• casting said suspension in a mold;
• drying said molded suspension to draw said water from said suspension;
• firing said dried suspension to form a ceramic network;
• and
• infusing a monomer to at least a portion of said ceramic network, wherein said mold is made from rubber and when said suspension is cast in said mold, a base of said mold is exposed, such that the step of drying said suspension comprises placing a slab of calcium sulfate in contact with said base, thereby drawing said water from said suspension in said slab.

A process for producing a ceramic network material from a ceramic suspension by casting said suspension in a tooth-shaped mold, wherein said suspension includes alumina particles dispersed in a medium containing deionized water with a pH in a range of about 4 to 5 and a concentration of polyvinyl alcohol in a range of about 0.5 to 2% by weight, comprising the steps of:

• casting said suspension in said mold;
• drying said molded suspension to draw said water from said suspension;
• firing said dried suspension in a furnace at a temperature in a range of about 1000.degree. to 1200.degree. C. to form a ceramic network;
• infusing lanthanum aluminosilicate glass to a coronal portion of said ceramic network to form a glass layer within said fired suspension with a thickness in a range of about 1 to 2 mm;
• and
• infusing a monomer to at least a portion of said ceramic network within said glass layer.

A process for producing a ceramic network material from a ceramic suspension by casting said suspension in an mold, wherein said suspension includes dispersed ceramic particles having diameters in a range of about 0.1 to 10 .mu.m in a medium containing deionized water with a pH selected from the group of ranges consisting of about 2 to 6 and about 8 to 11 and a concentration of polyvinyl alcohol in a range of about 0.1 to 2% by weight, comprising the steps of:

• casting said suspension in said mold;
• drying said molded suspension in a furnace at a temperature in a range of about 600.degree. to 1400.degree. C. to form a ceramic, open pore network;
• infusing at least a portion of said ceramic network with a silane coating agent;
• and
• infusing a monomer to at least a portion of said ceramic network.

A process for producing a ceramic network material from a ceramic suspension, wherein said suspension includes dispersed ceramic particles in a medium containing water and a dispersant, comprising the steps of:

• casting said suspension in a mold;
• drying said molded suspension to draw said water from said suspension;
• firing said dried suspension to form a ceramic, open pore network;
• infusing at least a portion of said ceramic network with a silane coating agent;
• and
• infusing a monomer to at least a portion of said ceramic network.