TCS Injection System and Cartridges: How to Get Started with Flexible Dentures

To start making flexible dentures, a lab needs a TCS injection system (an injector plus a furnace to melt the cartridge), an injection flask, thermoplastic cartridges and a few processing supplies. TCS (Thermoplastic Comfort Systems) makes four injector options, from the JP90 handheld unit to the Automatic Air Injector with Built-in Furnace, and Chase Dental Supply carries the injectors, kits, cartridges and accessories in one place.

Below we compare each injector, the cartridges that fit, and the supplies you need.

Key Takeaways

• The TCS Manual, Hydraulic and Automatic Air injectors all inject 25mm diameter cartridges.
• Each full size TCS injector yields approximately 30 cases per day; the Manual and Hydraulic units can reach up to 120 with additional furnaces.
• The Automatic Air Injector has a built-in furnace and self purging system but needs an air pressure hookup (minimum 140 psi).
• The JP90 handheld injector is built for 1 to 3 tooth unilaterals, partials of up to 5 consecutive teeth, and repairs.
• Basic and complete kits bundle the furnace, melting cylinder, bronze plugs and starter cartridges so you can run cases on day one.

What is a TCS injection system?

A TCS injection system is the equipment that heats a TCS thermoplastic cartridge until molten and forces it under pressure into a flasked case. The result is a one piece flexible partial or appliance with no monomer and no curing cycle.

Every system has the same core parts: a heat source, a melting cylinder that holds the cartridge, bronze plugs that seal the cartridge during melting, and an injector that delivers pressure. The differences are in how the pressure is generated and whether the furnace is separate or built in.

Which TCS injector should I choose?

Choose based on your volume, your bench space and whether you have shop air. Small and new labs often start with the Manual Injector or JP90, while busier labs that want push button consistency look at the Hydraulic or Automatic Air models.

TCS Manual Injector

The TCS Manual Injector is the most economical of the TCS injection units, and its main benefits are easy maintenance and longevity. It works with the TCS Digital Furnace or a similar furnace, yielding approximately 30 cases per day with one furnace and up to 120 with additional furnaces and melting cylinders.

The TCS Manual Injector Press and Furnace Kits come in basic and complete versions. The basic kit includes a Digital Furnace, Cylinder with Handle, Knock Out Rod and Stand, thick and thin Bronze Plugs, 6 cartridges of TCS resins and Mold Release Spray.

TCS Hydraulic Injector

The TCS Hydraulic Injector Basic Kit delivers equal pressure with every injection and requires no air connection. It uses the external TCS Digital Furnace and matches the Manual Injector’s output of approximately 30 cases per day, up to 120 with additional furnaces.

TCS Automatic Air Injector with Built-in Furnace

The TCS Automatic Air Injector with Built-in Furnace melts the cartridge and injects at the touch of a button. Because the furnace is built in, there is no need to move a hot cylinder of molten nylon from furnace to injector, and the self purging system eliminates hammering out cylinders.

It requires a hookup to air pressure (minimum 140 psi) and yields approximately 30 cases per day. The Automatic Air Injector Basic Kit adds an injection flask, Unbreakable and iFlex starter cartridges in medium Standard Pink, and Mold Release Spray.

TCS JP90 Handheld Injector

The JP90 is a lightweight, compact handheld injector for smaller work: 1 to 3 tooth unilaterals, partials or saddles of up to 5 consecutive teeth, and various repairs. It uses JP bullets instead of standard cartridges and requires an external heater (the TCS Digital Furnace).

The TCS JP90 Starter Kit with Digital Furnace includes the JP90, small and large JP bullets in Unbreakable and iFlex, a JP flask, 400 grams of TCS Putty, 2 waxed practice cases, a matrix pusher and 5 metal sprues.

Which cartridges fit TCS injectors?

The Manual, Hydraulic and Automatic Air injectors take 25mm diameter cartridges, which is the most popular cartridge size. The JP90 uses its own small and large JP bullets.

TCS fills 25mm cartridges with all three of its resins: Unbreakable (nylon), iFlex (polyolefin) and Karadent (semi-rigid microcrystalline polymer). For a typical starter order, labs pick up TCS Unbreakable Standard Pink cartridges and a pack of TCS iFlex Standard Pink Shade 2. Learn more about the materials in our TCS Unbreakable material guide and our Karadent by TCS guide.

Cartridge size within the 25mm line matters too. The thin bronze plug is used when melting large cartridges, and the thick bronze plug is used for medium or small cartridges.

What else do you need to process flexible dentures?

Beyond the injector, you need a flask, separator, sprue and waxing supplies, and tools to purge the cylinder. Most of these are included in the complete kits, but labs restock them often.

• Furnace and cylinder: the TCS Digital Furnace (110V) is a small digital furnace for melting thermoplastic nylons, used with the stainless steel Melting Cylinder with Handle and bronze disks. It is also available in 220V.
• Flask: the TCS Injection Flask (5 x 5 x 3 inches) is milled from one piece of aluminum with a knock-out plug that makes case removal easier. It is made in the USA.
• Separator and release: TCS EZ Flow separator is made for thermoplastics only, and TCS Mold Release Spray eases purging of the cylinder, bronze disks and cartridges.
• Sprues and wax: TCS 9.5 Sprue Wax matches the TCS flask opening for clean injections, and preformed palatal and lingual bar waxes save time.
• Purging: the TCS Knock-Out Rod and Knock-Out Stand clear the remaining cartridge and bronze disk from the melting cylinder after injection.

For flasking, use a stone suited to the job. Our guide to flasking vs mounting stone covers the differences.

How do you get started with your first flexible denture cases?

Start with one shade, one cartridge size and a kit, then expand once your workflow is stable. Most labs begin with Standard Pink in medium 25mm cartridges.

1. Choose an injector and order the basic or complete kit so the furnace, cylinder, plugs and release spray arrive together.
2. Stock a few packs of your main material and shade.
3. Read the TCS instructions for use for your unit and run the practice cases (the JP90 kit includes two waxed cases).
4. Set up a finishing station. Our guide to finishing flexible partials with TCS abrasives lists the wheels, stones and buffs in order.
5. Order sample models to show dentists what you can produce.

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Frequently Asked Questions

What size cartridge does a TCS injector use?

The TCS Manual, Hydraulic and Automatic Air injectors inject 25mm diameter cartridges. The JP90 handheld injector uses TCS JP bullets in small and large sizes.

Do TCS injectors need a separate furnace?

The Manual Injector, Hydraulic Injector and JP90 all require an external heater, the TCS Digital Furnace. The Automatic Air Injector has a built-in furnace, so the cartridge is melted and injected in the same unit.

How many cases per day can a TCS injector produce?

TCS lists approximately 30 cases per day for its full size injectors. The Manual and Hydraulic injectors can reach up to 120 cases per day with additional furnaces and melting cylinders.

Does the TCS Automatic Air Injector need compressed air?

Yes. It requires a hookup to air pressure with a minimum of 140 psi. If your lab has no air supply, the Hydraulic Injector requires no air connection.

What is the TCS JP90 used for?

The JP90 is a handheld injector for 1 to 3 tooth unilaterals, partials or saddles of up to 5 consecutive teeth, and various repairs. It weighs about 2 lbs and uses JP bullets heated in the TCS Digital Furnace.

The right TCS injection system depends on how many cases you run and how your bench is set up, but every option gives you consistent, monomer free flexible partials. See the full TCS (Thermoplastic Comfort Systems) collection at Chase Dental Supply, browse the dental lab and office supply brands guide, or email sales@chasedentalsupply.com for help with kits and voltage options.