How Should Dentists Cut Metal Crowns and Hard Materials Safely?

How Should Dentists Cut Metal Crowns and Hard Materials Safely?

Modern dentistry isn't just about skill — it's also about using the right tools for the right procedures. One of the most misunderstood clinical tasks is the removal of metal crowns, PFM bridges, or zirconia-based restorations. Many dentists instinctively reach for the high-speed airotor, only to damage the handpiece or burn through burs. Let's explore the right approach and tools.

Why NOT to Use Airotors for Metal?

Airotors are precision-driven tools designed to work at high speeds (up to 400,000 RPM), primarily meant for:

Enamel and dentin preparation, Composite finishing, Crown cutting (non-metallic). 

However, metallic restorations are dense and hard, requiring torque more than speed. Using an airotor on these can result in:

Burnt out turbines, Overheated bearings, Premature wear of diamond burs, Compromised safety and control.

The Right Way to Cut Metal Crowns

To cut metal, zirconia, or other hard materials effectively, torque and control are more important than speed. Here’s what you should use:

Micromotor / Slow-Speed Handpiece (with torque)

Use a micromotor with contra-angle or straight handpiece at low-to-medium speed (20,000–40,000 RPM). These are ideal for cutting metals and offer better control.

Tungsten Carbide Burs - Specially designed carbide burs for metal cutting are available in various shapes and sizes. These burs have spiral flutes that can efficiently slice through:

PFM crowns, Full metal crowns, Amalgam or heavy composites, Temporary crowns with metal reinforcement, Crown Splitters and Metal Cutting Discs

When space permits, metal-cutting discs on a straight handpiece or even manual crown splitters can be used for additional precision without damaging nearby structures.

Tips for Safe Metal Crown Removal

Section the crown in two to relieve tension and make removal easier, Always cool with water spray to prevent overheating and thermal damage, Ensure burs are sharp and not overused, Train your assistant to handle slow-speed suction and illumination properly, Use magnification for better precision and protection of surrounding tissue.

 

BRIXO’s Insight - At BRIXO, we emphasize preserving the life of your instruments and improving your practice efficiency.

While our BRIXO Dental Diamond Burs and Airotors are crafted for superior performance in clinical procedures, we strongly advise against using them for metal cutting. That’s not their battlefield. Use the right tool for the right job,  Train your staff regularly, Extend the life of your equipment and ensure patient safety.

In Summary -  Metal crowns and hard prosthetics require torque, not speed. Use a slow-speed micromotor + carbide bur combo — not your airotor.  Dentists who know the difference preserve tools, time, and trust.

BRIXO Dental – The Name You Can Trust.  Trusted by over 1000 dentists nationwide