Methods for manufacturing endodontic instruments from powdered metals

A method of manufacturing an endodontic instrument or an intermediate product, comprising:

• (a) providing a mold having a mold cavity that at least partially corresponds to or approximates a shape of an endodontic file or an intermediate product having a proximal end and a distal end, that is essentially straight between the proximal end and the distal end, that has a taper extending along a length between the proximal end and the distal end, that includes an at least partially formed cutting edge, and that has a length and a width so as to be readily insertable within a root canal of a tooth;
• (b) inserting a molding material comprising a metal powder into the mold cavity and shaping the molding material to form a green molded part having a proximal end and a distal end, that is essentially straight between the proximal end and the distal end, that has a taper extending along a length between the proximal end and the distal end, that includes an at least partially formed cutting edge, and that has a length and a width so as to be readily insertable within a root canal of a tooth;
• and
• (c) sintering the green molded part to form a solid metal part.

A method of manufacturing an endodontic instrument or an intermediate product, comprising:

• (a) providing a mold having a mold cavity that at least partially corresponds to or approximates a shape of an endodontic file or an intermediate product having a proximal end and a distal end, that is essentially straight between the proximal end and the distal end, that has a taper extending along a length between the proximal end and the distal end, that includes an at least partially formed cutting edge, and that has a length and a width so as to be readily insertable within a root canal of a tooth;
• (b) inserting a molding material comprising a metal powder and a binder into the mold cavity and shaping the molding material to form a green molded part having a proximal end and a distal end, that is essentially straight between the proximal end and the distal end, that has a taper extending along a length between the proximal end and the distal end, that includes an at least partially formed cutting edge, and that has a length and a width so as to be readily insertable within a root canal of a tooth;
• (c) causing or allowing the binder to at least partially harden;
• (d) sintering the green molded part to form a solid metal part;
• and
• (e) cold working the solid metal part to modify the at least partially formed cutting edge.