TCS Unbreakable: The Complete Flexible Partial Denture Material Guide

TCS Unbreakable is a high performance nylon thermoplastic used to injection mold lightweight, flexible partial dentures with tissue colored clasps and no metal. It is made by TCS (Thermoplastic Comfort Systems), and Chase Dental Supply carries the full range of TCS Unbreakable flexible partial material in cartridges, JP bullets and bulk, plus the injectors and finishing tools that go with it.

This guide covers what the material is, which shades and cartridge sizes exist, how it compares to the other TCS resins, and what a lab needs to start running cases.

Key Takeaways

• TCS Unbreakable is a nylon thermoplastic known for strength and memory, designed for flexible removable partials.
• It comes in five shades: Light Pink (1), Standard Pink (2), Light-Dark Pink (3), Dark Pink (4) and Natural (N).
• Cartridges are sold in Small, Medium and Large sizes in 22mm, 25mm and 28mm diameters, with 25mm fitting every TCS injector.
• Each 5 cartridge pack ships with delivery bags, patient care instructions and TCS appliance cleaner samples for the patient.
• Repairs, air bubbles, clasp additions and one tooth additions can be handled with the Hot Air Welder or the JP90 injector.

What is TCS Unbreakable flexible partial material?

TCS Unbreakable is an extremely resilient, high performance nylon thermoplastic that TCS describes as popular for its strength and exceptional memory. It is injected into a flasked case to produce a durable, lightweight and aesthetic removable flexible partial.

Because it is a thermoplastic, there is no liquid monomer to mix. TCS lists it as biocompatible and ideal for patients who are allergic to acrylic monomer, and notes its low water absorption.

Flexible partials made from Unbreakable use clasps of the same tissue colored material instead of metal. That is the main reason dentists prescribe them for patients who do not want visible metal clasps or who want a lighter appliance than a traditional acrylic and metal partial.

Who uses it?

Dental labs that fabricate removable prosthetics are the main buyers. Ortho and specialty labs that already run thermoplastic injection often add Unbreakable partials as a service line, and dental schools use it to teach flexible partial technique.

Dentists use it through their lab. On the chairside side, TCS sells a Doctor Chairside Adjustment Kit so practices can make small adjustments on Unbreakable partials after delivery.

Which TCS Unbreakable shades and cartridge sizes should I choose?

Pick the shade that matches the patient’s tissue and the cartridge size that matches the case and your injector. Most labs stock Standard Pink in 25mm medium cartridges and add the other shades and sizes as case mix demands.

Shades

TCS Unbreakable is offered in Light Pink (Shade 1), Standard Pink (Shade 2), Light-Dark Pink (Shade 3), Dark Pink (Shade 4) and Natural (Shade N). TCS Unbreakable Standard Pink, 5 cartridges per pack is the everyday shade for most labs. TCS Unbreakable Light Pink Shade 1 and TCS Unbreakable Dark Pink Shade 4 cover lighter and darker tissue, while TCS Unbreakable Natural Shade N suits cases that call for a neutral tone. TCS also offers free personalized shade guides.

Cartridge sizes and diameters

Cartridges come in Small, Medium and Large, in 22mm, 25mm and 28mm diameters, plus 25mm versions with a tab and a Large 25mm cartridge with a nozzle tip. The 25mm diameter is the one to standardize on if you run TCS equipment, because the TCS Manual, Hydraulic and Automatic Air injectors all inject 25mm cartridges.

The 22mm and 28mm sizes exist so labs running other brands of injection units can still use TCS material. Check your injector’s manual before ordering a new diameter.

TCS Unbreakable vs iFlex vs Karadent: what’s the difference?

Unbreakable is nylon, iFlex is polyolefin and Karadent is a semi-rigid microcrystalline polymer. All three are TCS thermoplastics, but they suit different prescriptions.

• Unbreakable: nylon with strength and memory, the classic flexible partial material.
• iFlex: a highly translucent polyolefin that TCS positions as an alternative to nylon. It is easy to finish and polish and has virtually no water absorption, which helps it resist stains and odors.
• Karadent: semi-rigid, for cases that need more stability, such as full dentures, semi-flexible partials, clear clasps, frameworks and nightguards. See our Karadent by TCS shades and sizes guide.

If you are weighing flexible against conventional partials for a given patient, our article on flexible partials vs acrylic partials walks through the tradeoffs.

How do you process a TCS Unbreakable partial?

The short version: wax and flask the case, melt the cartridge, inject it, then deflask and finish. The exact times and temperatures come from TCS’s instructions for use, so follow those for your injector.

Setup and flasking

Denture teeth need mechanical retention because nylon does not chemically bond to acrylic teeth. TCS Twist Drills create the diatoric retention in acrylic teeth, and TCS Cement secures the teeth in the stone before injection. Preformed TCS Palatal Wax is made at the recommended thickness for an Unbreakable palate, which saves waxing time.

Your choice of flasking stone matters too. Our sister guide on flasking vs mounting stone explains what to look for.

Injection

The cartridge is melted in a furnace and injected into the flask. TCS offers manual, hydraulic and automatic air injectors, plus the JP90 handheld unit for small cases, all covered in our TCS injection system and cartridges guide.

Finishing

Thermoplastics finish differently than acrylic, with dedicated wheels, rubberizing and a soft polishing buff. Our step by step article on finishing flexible partials with TCS abrasives covers the full sequence.

Can a TCS Unbreakable partial be repaired or added to?

Yes. Unbreakable can be repaired with re-injection, and small repairs, air bubbles, clasps and one tooth additions can be made with the Hot Air Welder or the JP90 injector.

The TCS Hot Air Welder melts a piece of Unbreakable, such as a leftover injected sprue, together with the repair area using hot air only. It runs on butane and ships empty. For larger repairs that need flasking and re-injection, TCS Fusing Liquid is applied to the bonding area right before injection.

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Frequently Asked Questions

What is TCS Unbreakable made of?

TCS Unbreakable is a high performance nylon thermoplastic. It is injected into a flask to make removable flexible partial dentures and is monomer free.

Is TCS Unbreakable safe for patients with acrylic allergies?

TCS describes Unbreakable as biocompatible and ideal for patients who are allergic to acrylic monomer. The final material choice should always be made by the treating dentist.

What shades does TCS Unbreakable come in?

Unbreakable is available in Light Pink (Shade 1), Standard Pink (Shade 2), Light-Dark Pink (Shade 3), Dark Pink (Shade 4) and Natural (Shade N). TCS also offers free personalized shade guides.

Which cartridge size fits TCS injectors?

The TCS Manual, Hydraulic and Automatic Air injectors all inject 25mm diameter cartridges. TCS also makes 22mm and 28mm cartridges for labs that run other injection units.

Can a TCS Unbreakable partial be repaired?

Yes. It can be repaired by re-injection, using TCS Fusing Liquid on the bonding area. Small repairs, air bubbles, clasps and one tooth additions can be done with the TCS Hot Air Welder or the JP90 injector.

TCS Unbreakable gives labs a proven, monomer free way to offer metal free flexible partials, with the shades, cartridge sizes and repair options to support it long term. Browse the complete TCS (Thermoplastic Comfort Systems) line at Chase Dental Supply, or reach our team at sales@chasedentalsupply.com with questions about shades, sizes or injector compatibility.