Sleep & Appliances

Every sleep and occlusal appliance case at Dani Dental begins with a digital intake review. Clinicians send either a PVS or alginate impression, a stone model, or an intraoral scan file (STL or OBJ via our secure upload portal). The technician assigned to the case reviews the bite registration, the prescribed design type, and any clinician notes before a single milligram of material is touched. That technician is named on the case ticket, and their direct extension is on the delivery slip. For sleep appliances, Dani Dental builds in the Dorsal fin, EMA, Herbst, and SUAD design families. Each device is fabricated from BPA-free thermoplastic or acrylic per the clinician's material preference. Dorsal and EMA devices use precision hardware sourced from a single named supplier, not rotated between lowest-bid vendors. Bite registration is verified against the submitted records before the anterior stop is set. If the bite registration is ambiguous, the technician calls the office before fabricating rather than guessing and shipping. Occlusal splints and nightguards follow a flat-plane or anterior-guidance protocol based on the clinician's prescription. Hard acrylic devices are processed on a pressure-pot cycle calibrated at Dani's Arizona facility. Soft dual-laminate nightguards use a 2mm inner EVA bonded to a 1mm outer copolyester shell, heat-pressed and trimmed to cast with visible tissue stops. Every device is marked with the patient ID, device type, and technician initials before packaging. DSO accounts with multiple locations receive a consolidated weekly delivery manifest listing every case by office, patient ID, and device type. Each location's turnaround is tracked separately so practice managers can see exactly where a given appliance is in the queue at any point. Billing is consolidated at the account level, not per-location, which removes the administrative fragmentation that kills multi-office appliance programs. Quality verification at the bench includes occlusal indicator film testing on every bite device and a hardware actuation check on every adjustable-advancement appliance before the case seals. A remake is documented internally as a defect event, not simply re-queued, which is how Dani holds the line at a sub-2.5% remake rate rather than letting drift accumulate invisibly across quarters.