1243 E Broadway Rd, Tempe AZ · (480) 449-09093433 E Ft Lowell Rd, Tucson AZ · (520) 795-7970
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PROCEDURE

apnea mouth guard

Dani Dental fabricates custom mandibular advancement devices using digital impressions and CAD-milled frameworks, delivering apnea mouth guards in 5 business days or fewer. Since 1993 our Arizona bench has held a remake rate below 2.5%.

  • Margins verified against your prescription
  • Pre-paid two-way shipping
  • Talk to the technician who built it
  • Full digital workflow

Every apnea mouth guard case at Dani Dental begins with a structured intake: the prescribing dentist submits either a digital scan file (STL via intraoral scanner) or a PVS impression with a protrusive bite registration. We accept Trios, iTero, and Medit scan formats without conversion fees or file-reformatting delays. That single-format flexibility cuts the intake lag by a full business day compared to labs that require proprietary submission portals. From the digital file, our CAD team uses exocad DentalCAD to design the appliance framework. Titration range, fin geometry, and vertical dimension are all specified at the design stage so the dentist reviews a PDF proof before a single block is milled. That proof-before-mill step is the primary reason our remake rate stays below 2.5%. A design question caught at the proof stage costs one email. The same question caught after milling costs a full remake cycle. Milling runs on a Roland DWX-52DCi five-axis unit loaded with the appropriate blank: hard PMMA for rigid monoblock designs, dual-laminate Erkodur-h for soft-hard construction, or Polyamide-12 nylon for patients who grind through standard acrylic within 12 months. Material selection is documented on the case ticket and included in the delivery summary so the dentist has a clear record for the patient file. No guesswork on what arrived or why. Post-mill, each appliance goes through a bench-finishing and QC step by a named technician, not a production-line inspector. The technician verifies the protrusive range against the prescribed millimeter measurement, checks occlusal contacts on the articulated model, and signs off on the case ticket. That signature ties accountability to a person, not a department. If a dentist calls with a fit question, the technician who finished the case takes that call directly, same business day. Delivery ships via tracked courier with an expected arrival date confirmed by email at the time of dispatch. Dentists running active sleep therapy programs can request a standing-order schedule: cases submitted by Thursday noon ship by Wednesday of the following week, giving front-desk staff a predictable delivery window to pre-schedule the delivery appointment. That scheduling reliability directly reduces the no-show rate on appliance-delivery visits, which is where sleep programs most commonly lose patient momentum.

HOW IT IS BUILT

From prescription to seated case.

01

Prescription in

Send a scan file or a model with your RX. A technician reads your intent before any design begins.

02

Design & verify

We design to your margin and occlusion, then verify the fit against your prescription before it ships.

03

Build at the bench

Milled, pressed, or hand-layered as the case calls for, finished by a named technician.

04

Back to your chair

Pre-paid shipping returns the case ready to seat, with the technician reachable if anything needs an adjustment.

This is our standard pipeline. The exact steps for apnea mouth guard are being detailed and will appear here.

MATERIALS

What goes in the mouth.

The material options for apnea mouth guard, from zirconia and lithium disilicate to hand-layered porcelain, are being written up. Ask for a Doctor Kit and a technician will talk through the right choice for your case.

CASE WORK

Judge the work on its result.

Before-and-after case work for apnea mouth guard is being photographed at the studio. The best proof is a case of your own. Send one and see the finish on your chair.

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COMMON QUESTIONS

What dentists ask about apnea mouth guard

What scan or impression formats does Dani Dental accept for sleep appliance cases?
We accept STL files from Trios, iTero, and Medit scanners at no conversion fee. For practices still using analog workflows, a PVS impression with a protrusive bite registration ships to our Arizona lab and is poured in-house. Either path targets the same 5-business-day fabrication window. If you are unsure whether your scanner exports a compatible file format, call our lab line and a technician will confirm before you submit the first case.
Which mandibular advancement device designs does the lab fabricate?
We currently offer three frameworks: a hard PMMA monoblock for maximum durability, a dual-laminate soft-hard design using Erkodur-h sheet for patients who report discomfort with rigid appliances, and a milled Polyamide-12 nylon design for high-bruxism patients who fracture standard acrylic within 12 months. The prescribing dentist selects the design on the case form; we document the selection in the delivery summary for the patient record.
How does the proof-before-mill step work and why does it matter?
After we model the appliance in exocad DentalCAD, we generate a PDF proof showing the proposed framework design, protrusive range in millimeters, and vertical dimension. The dentist reviews and approves that proof before milling starts. Design questions caught at this stage resolve in one email exchange. The same question caught post-mill requires a full remake. That single gate is the primary reason our remake rate sits below 2.5% on sleep appliance cases.
What is the typical turnaround time for a custom apnea mouth guard?
Five business days from the date we receive an approved scan or poured model. Digital cases that arrive with a valid STL and a clear protrusive registration tend to hit the low end of that window. Analog cases add one day for pouring and mounting. Practices on a standing-order schedule, submitting cases by Thursday noon, can expect delivery by the following Wednesday, which maps neatly to a pre-scheduled patient delivery appointment.
Can I request a specific titration range or fin design for a particular patient?
Yes. The case form includes fields for maximum protrusive range in millimeters, fin geometry preference (dorsal-fin versus telescoping), and any vertical dimension notes from the clinical exam. Prescriptions outside our standard ranges go to a technician for a brief case-planning call before we generate the proof. That call usually runs under 10 minutes and eliminates the back-and-forth that stretches turnaround at labs with no direct technician contact.
What happens if the appliance does not fit at the delivery appointment?
Call the technician who signed off on the case, same business day. The delivery summary includes that technician's direct line. If the fit issue traces to a lab error in our QC review, we remake the appliance at no charge and prioritize it in the production queue, targeting a 3-business-day return. If the issue traces to a change in the patient's occlusion between impression and delivery, we document the adjusted registration and fabricate a corrected appliance at a reduced remake fee.
Does Dani Dental support practices running high-volume sleep therapy programs?
Yes. Practices submitting five or more sleep appliance cases per month can set up a standing-order schedule with a dedicated lab contact and a confirmed weekly ship day. Billing consolidates to a single monthly statement with line-item case detail. That billing structure is designed for practices that want to run sleep therapy as a tracked revenue line, not a scattered referral add-on. Call our lab to discuss whether the volume threshold fits your current or projected caseload.
Is a prescription or sleep study required before the lab will fabricate the appliance?
Dani Dental is a dental laboratory. We fabricate to the prescribing dentist's written appliance prescription. Whether the dentist requires a polysomnogram or home sleep test from the patient before writing that prescription is a clinical and regulatory decision the dentist makes within their scope of practice. We do not review or store patient sleep study data. If you have questions about appliance prescription standards in Arizona, the Arizona Dental Association's sleep dentistry guidance is a starting point.

REQUEST A DOCTOR KIT

Send us a apnea mouth guard case.

Request a Doctor Kit and we will mail RX pads, a shade guide, and pre-paid shipping. Run your first cases through the studio and judge the result on your own chair.

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