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

mouthguard

Dani Dental fabricates custom mouthguards and occlusal appliances with 5-to-7 business-day turnaround from digital scan or PVS impression. Designed for the dentists who refer their bruxism and sleep-apnea cases back to us year after year, each appliance is built to the prescri...

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

Every mouthguard case at Dani Dental opens with a material and occlusion consultation, not a form submission that disappears into a queue. When the prescription arrives, the assigned technician reviews the bite registration, the patient's arch dimensions, and the clinician's stated goals before a single piece of acrylic or thermoplastic is touched. That front-end review is where most lab errors are caught and corrected, not during the remake call three weeks later. For digital workflows we accept STL files from any major intraoral scanner, including iTero, 3Shape TRIOS, and Carestream. The digital file feeds directly into our CAD station, where the technician models the appliance in 3Shape Dental System software and reviews occlusal contacts in articulation simulation before milling or pressing. Print-and-press fabrication on hard acrylic appliances runs on our in-house milling unit, keeping the chain unbroken. No third-party milling vendor, no blind handoff, no refit guessing. For practices still sending PVS impressions, the impression enters the same workflow after a die pour and digital scan of the resulting model. Quality is not tiered by submission method. A PVS impression gets the same CAD review and the same named-technician accountability as a direct scan file. The material hierarchy covers three tiers: hard acrylic for heavy bruxers, dual-laminate for patients who need both rigidity and cushion, and thermoplastic for lower-force bite guards and sports applications. Clinicians specify the tier on the Rx; if the bite registration or wear history suggests a mismatch, the technician calls before fabricating, not after. Every finished appliance ships with a printed fit and adjustment guide for the delivering clinician, the technician's direct phone line, and a no-questions remake policy that covers fit issues within 30 days of delivery. Turnaround is 5 to 7 business days from confirmed receipt of a complete case. Rush cases, when capacity allows, complete in 3 business days. The technician on your case is the technician who answers the phone. No call center, no ticket system.

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 mouthguard are being detailed and will appear here.

MATERIALS

What goes in the mouth.

The material options for mouthguard, 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 mouthguard 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 mouthguard

What file formats and impression types does Dani Dental accept for mouthguard cases?
We accept STL files from iTero, 3Shape TRIOS, Carestream, and most other common intraoral scanners. PVS, polyether, and alginate impressions are also accepted. Alginate is poured and scanned on arrival due to dimensional stability; PVS and polyether process directly. Cases submitted by digital scan typically enter the CAD queue within one business day of file receipt.
What is the standard turnaround time for a custom mouthguard?
Standard fabrication is 5 to 7 business days from confirmed receipt of a complete case, meaning a readable scan or usable impression plus a signed Rx with material spec. Rush turnaround of 3 business days is available on a capacity basis. Confirm rush availability when you call in the case. Clock starts at receipt, not at submission, so complete cases move fastest.
Which materials are available and how do I choose between them?
Dani Dental offers three material tiers: hard acrylic for heavy bruxers requiring maximum durability, dual-laminate for patients who need rigidity on the occlusal surface with cushioning against the tissue, and thermoplastic for lighter bite guards and sports applications. If the bite registration or wear history in the case notes suggests a mismatch with the prescribed tier, the assigned technician calls before fabrication begins.
Can I specify occlusal contacts or anterior guidance on the appliance Rx?
Yes. The Rx form includes fields for centric stops, canine guidance preference, anterior discluding ramp, and freedom in centric. If your case involves a specific gnathologic or neuromuscular protocol, note it on the Rx and the technician reviews it before CAD modeling starts. Cases with complex occlusal requirements are flagged for a brief phone consult before fabrication, not after.
What is the remake policy if the appliance does not seat or fit correctly?
Dani Dental covers remakes at no charge within 30 days of delivery for any fit issue that traces to fabrication. Send the appliance back with a note describing the seating problem and the original bite registration if available. The technician who built the original case handles the remake. Turn time on remakes is 3 to 5 business days. Our 2024 data puts the overall remake rate below 2.5 percent across all removable appliance cases.
Does Dani Dental fabricate sleep apnea appliances and mandibular advancement devices?
Yes. We fabricate titratable mandibular advancement devices alongside standard occlusal guards. The Rx must include a protrusive bite registration at the prescribed starting position and the titration range in millimeters. We work with the prescribing clinician's preferred device design or can recommend a design based on the patient's arch anatomy and the clinician's titration protocol. Lead time matches the standard 5-to-7-day window.
Who do I contact if I have a question about a case in progress?
Every case ships with the direct phone number of the named technician who fabricated it. During fabrication, the same technician is reachable by phone or email during business hours. Dani Dental does not route clinical case questions through a call center or a ticketing system. If you call the lab line, the person who picks up can pull your case file and answer within the same conversation.
How does Dani Dental handle mouthguard cases from practices that send high volume?
High-volume accounts, meaning three or more active cases per week, are assigned a primary technician and a secondary backup so case continuity holds when one technician is on a complex full-arch build. Volume pricing tiers are available starting at 10 appliances per month. Call the lab directly to discuss the volume structure. There is no procurement portal or multi-week onboarding cycle. Most new accounts are set up and shipping within one week of the first call.

REQUEST A DOCTOR KIT

Send us a mouthguard 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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