football mouth guard

Every football mouth guard at Dani Dental starts with a model or a digital file, not a stock tray. Dentists submit either a polyvinyl siloxane impression, a stone model, or an STL exported from any major intraoral scanner. The lab accepts Ditto, iTero, 3Shape TRIOS, and Medit formats without file conversion on the dentist's end. From that starting point the fabrication technician assigns the case under the Dani Dental named-technician protocol, meaning one bench-certified technician owns the file, the vacuum-forming run, and the QC check before the guard ships. The lamination process uses a dual-layer ethylene vinyl acetate (EVA) press sequence. The inner layer is a softer 3mm EVA that conforms tightly to the occlusal anatomy and labial surfaces. The outer layer is a denser 4mm EVA that absorbs and distributes impact load. Both layers are heat-bonded under controlled pressure on the Erkodent Erkoform-3d motion unit, which maintains consistent temperature and dwell time across the palatal vault and the buccal flanges. Guards trimmed by hand instead of by a heat-formed flange line introduce irregularities that cause athlete non-compliance; every Dani guard is trimmed along the anatomical flange, not to a generic silhouette. Color integration happens at the outer-layer lamination stage, not as a surface coating. Team colors selected from the 12-plus stock EVA palette bond through the full thickness of the outer layer, so the color does not flake, peel, or fade through a season of use. Dentists ordering for teams or group practices can submit a single prescription with multiple athlete names; the lab batches the cases, fabricates on the same production run, and ships labeled by athlete name for chair-side distribution. Quality checks before shipment include a seating-fit review on the original model, an occlusal clearance verification (minimum 3mm posterior clearance confirmed with a feeler gauge), and a flange extension check against the mucogingival junction landmarks on the cast. Any guard that does not pass all three checks is re-pressed the same day, not flagged for the next production cycle. The result is a guard that arrives ready to dispense, not one that requires chair-side adjustment. Dentists who have not yet opened a Dani Dental lab account can request one through the Doctor Kit form. The kit includes pre-addressed impression packaging, a laminate color card with the full 12-plus stock palette, and the direct phone number for the technician assigned to their region. Turnaround clock starts the business day the model or STL is received and confirmed usable, with a 24-hour hold notification if any file or impression has a defect that would affect fit.