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

custom mouth guard

Dani Dental fabricates custom occlusal guards and athletic mouth guards from high-density thermoformed and hard-acrylic materials, with a 5-business-day standard turnaround and same-technician continuity on every case.

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

Every custom mouth guard case at Dani Dental opens with a material-selection conversation. The lab distinguishes between three fabrication pathways: hard acrylic for bruxism management and occlusal splint therapy, dual-laminate thermoformed (hard outer, soft inner) for moderate parafunction or patients who have rejected hard-only appliances, and single-layer thermoformed EVA or copolyester for athletic protection. That three-pathway triage, not a one-size-pulls-the-tray approach, determines which workflow touches the case first. Impression handling follows the Dani Dental Dimensional Accuracy Protocol. Polyvinyl siloxane and polyether impressions are poured within 45 minutes of intake to minimize distortion. Alginate cases are poured on arrival, no exceptions. Stone selection is ADA Type III or Type IV depending on the guard type. Hard acrylic appliances require Type IV. This is not a preference; it is a documented lab standard enforced at the pour station. For hard acrylic guards, the lab uses a pressure-pot cured heat-processed acrylic cycle. Curing under 20 psi for 30 minutes at 160 degrees Fahrenheit reduces porosity and produces a denser cross-link than bench-cure methods. After deflasking, each guard is trimmed on the die model, checked for occlusal contact distribution using articulating film at 40 microns, and adjusted until the contact pattern is even within the working arch. The technician who pours the model is the same technician who finishes the guard. Thermoformed guards run through a calibrated Biostar or Erkodent pressure-forming unit set to material-specific temperature and dwell-time profiles. Sheet thickness is confirmed by micrometer before forming. Post-form fit is checked against the original stone model, not the working duplicate. Any guard that rocks, gaps beyond 0.3 mm at the posterior margin, or shows air voids at the anterior teeth is re-formed before it leaves the department. Shipping and communication close the loop. Each guard ships in a labeled case with the fabricating technician's direct phone extension and a one-page adjustment reference that covers chairside reduction protocols for both acrylic and thermoformed materials. If the doctor calls with a fit question, the technician who made the guard takes the call, not a general intake line. That single-contact accountability has kept Dani's guard remake rate below 2.5 percent across the 2023 and 2024 production years.

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 custom mouth guard are being detailed and will appear here.

MATERIALS

What goes in the mouth.

The material options for custom 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 custom 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.

Send a case

COMMON QUESTIONS

What dentists ask about custom mouth guard

What impression materials does Dani Dental accept for custom mouth guard fabrication?
The lab accepts polyvinyl siloxane, polyether, and alginate impressions. PVS and polyether are poured within 45 minutes of intake. Alginate is poured on arrival to prevent distortion. Intraoral scans in STL format are accepted for thermoformed guard cases and routed to the digital workflow for model printing before fabrication begins. If you are unsure which format works for your case, call the lab and ask for the guard department directly.
What is the difference between a hard acrylic guard and a dual-laminate guard?
Hard acrylic guards are pressure-pot cured and provide maximum rigidity for heavy bruxers and occlusal splint therapy cases. Dual-laminate guards have a hard outer shell for durability bonded to a soft inner layer that contacts the teeth, which some patients tolerate better than full-hard appliances. The choice depends on parafunctional severity and patient history. Dani Dental's technicians will discuss both options before fabrication if the prescription does not specify a material.
How long does fabrication take, and is rush service available?
Standard turnaround is 5 business days from impression arrival. Rush 2-business-day service is available for athletic guard cases and select occlusal guard types. Rush cases must be called in before noon Arizona time on the day the impression ships so the lab can stage the incoming work. Rush availability is not guaranteed during peak periods; call ahead to confirm capacity before promising a delivery date to your patient.
Can Dani Dental fabricate guards for implant-supported restorations?
Yes. Guards fabricated over implant-supported crowns or full-arch implant prosthetics require a separate stone model poured from a verified impression or scan body workflow. The technician notes implant positions and avoids localized pressure points over fixture sites during the contact-distribution check. Prescription notes should flag all implant locations and crown materials so the adjustment reference shipped with the guard is accurate for your chairside delivery.
What should I write on the prescription for a custom athletic mouth guard?
Include the patient's arch (upper only in most athletic cases), preferred material thickness if you have a preference (3 mm standard, 4 mm heavy-contact sports), any existing crowns or bridges that need relief, and the sport or activity. If the patient wears orthodontic retainers or has a fixed lingual wire, note that on the form. A complete prescription reduces back-and-forth and keeps the case on the 5-day track.
How does Dani Dental handle occlusal guard cases that require articulation?
Cases that need mounted articulation for splint therapy or complex occlusal equilibration should include a bite registration and, ideally, opposing impressions. The lab mounts models on a semi-adjustable articulator and checks the guard in excursive movements before finishing. This step adds roughly one business day to the standard timeline. Prescription notes should specify whether anterior guidance, canine guidance, or bilateral balanced occlusion is the target for the appliance.
What is included in the shipping package when a guard is delivered?
Every guard ships in a labeled storage case alongside a one-page adjustment reference covering chairside reduction protocols for both acrylic and thermoformed materials, the fabricating technician's direct phone extension, and care instructions formatted for patient handout use. The technician's extension is printed on the case label and the reference sheet so the number is accessible at the delivery appointment if an adjustment question comes up on the spot.
Does Dani Dental offer quantity pricing for practices ordering guards regularly?
Yes. Practices submitting 8 or more guard cases per month can request a standing-account pricing conversation with lab management. Pricing structure is discussed directly with the practice, not routed through a procurement portal. Call the lab and ask for the account setup line. DSO groups managing multiple locations can consolidate guard orders under a single account with unified billing, which several Arizona-based group practices currently use to simplify monthly reconciliation.

REQUEST A DOCTOR KIT

Send us a custom 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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