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

mouth guard

Dani Dental fabricates custom occlusal guards, sport mouth guards, and bruxism appliances with a 5-business-day standard turnaround. Every appliance is designed from a digital scan or PVS impression, milled or pressure-formed in-house at our Arizona lab, and reviewed by a name...

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

Every mouth guard case at Dani Dental starts with scan acceptance. We accept intraoral STL files from any major scanner (iTero, 3Shape Trios, Medit, Carestream) and conventional PVS impressions poured in-house in Type IV stone. Digital cases bypass the pour-and-trim step entirely, which cuts an average of 1.5 days off the fabrication window. The technician assigned to your case reviews the occlusal records before fabrication starts, flagging any interferences or arch dimension notes before material is cut. For bruxism and occlusal appliances, we use a dual-workflow system. Hard acrylic guards are milled on our in-house 5-axis milling unit from PMMA pucks, then hand-finished and polished to a smooth occlusal surface. Pressure-formed guards are fabricated on a calibrated vacuum-forming unit using layered EVA or dual-laminate (hard core, soft facing) sheet stock. Material selection follows the prescription the doctor sends. If the prescription is open, our technician will call or text within 4 business hours with a recommendation based on the arch scans and any brux severity notes in the Rx. Sport mouth guards follow the same digital-first intake. The guard is pressure-formed over a stone or printed model, then trimmed to a posterior stop at the second molar. We do not produce generic boil-and-bite devices. Every unit is custom to the patient model. Color selection, team logo lamination, and thickness are confirmed before fabrication via a one-page digital Rx form included in the Dani Dental Doctor Kit. QC happens at two checkpoints. The first is dimensional: the appliance is seated on the original model or printed model and checked for full seating, border extension, and occlusal clearance. The second is surface finish: edges are checked under magnification for flash or rough borders that could irritate soft tissue. Anything that does not pass both checks is remade at no charge, no explanation required. The shipping label is printed only after both checkpoints are signed off by the assigned technician. Dentists who refer mouth guard cases regularly can set up a standing prescription profile in the Dani Dental portal. The profile stores default material selection, thickness preference, and posterior stop position so you do not re-enter the same preferences on every Rx. New offices can have a profile live within one business day of their first case submission.

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 mouth guard are being detailed and will appear here.

MATERIALS

What goes in the mouth.

The material options for 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 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 mouth guard

What impression or scan formats do you accept for mouth guard cases?
We accept STL files from iTero, 3Shape Trios, Medit, and Carestream scanners, as well as conventional PVS or alginate impressions. Digital files are preferred because they skip the pour-and-trim step and reduce the standard turnaround by roughly 1.5 days. If you send a physical impression, we pour it in Type IV stone in-house and proceed from there. Either path produces the same quality result.
How long does a standard custom mouth guard take to fabricate and ship?
The standard turnaround is 5 business days from scan or impression receipt to shipping label. A 48-hour rush option is available for single-arch guards when we receive a confirmed intraoral scan by 10 a.m. local time. Rush cases carry a flat expedite fee listed in the current Dani Dental fee schedule. Physical impression cases are not eligible for the 48-hour rush because the pour step adds at least one additional day.
Which mouth guard materials do you offer, and how do I choose?
We stock three configurations: hard acrylic (milled PMMA), soft EVA, and dual-laminate (hard PMMA core with soft EVA facing). Hard acrylic is recommended for moderate-to-severe bruxism. Soft EVA suits lighter clenching and sport use. Dual-laminate balances retention with comfort for patients who have rejected hard guards before. If your Rx leaves material open, a technician will contact you within 4 business hours with a recommendation based on your scan data and any clinical notes provided.
Do you fabricate sport mouth guards, or only occlusal/bruxism appliances?
Both. Sport guards are pressure-formed over a custom model to the patient's arch. We offer single-color, dual-color, and team-logo lamination options. Posterior extension stops at the second molar by default. Every unit is custom to the patient model. We do not produce generic boil-and-bite devices. Color and thickness preferences are confirmed via the digital Rx form before fabrication begins.
What happens if the guard does not fit correctly when it arrives?
Any appliance that does not seat fully, shows border extension errors, or has a surface finish issue is remade at no charge. No prior authorization is needed. Contact the technician listed on your case card, describe the fit issue, and ship or scan the original for reference. The remake ships within the standard 5-business-day window from the date we receive the fit report. Our remake rate across all appliance types runs below 2.5% based on 2024-2025 production data.
Can I set up a standing Rx profile to avoid re-entering preferences on every guard case?
Yes. Dentists who refer guards regularly can store a default material, thickness, and posterior stop preference in the Dani Dental portal. Once the profile is active, new cases default to those settings and you only need to override when something changes. New offices can have a standing profile live within one business day of their first case submission. Setup instructions are included in the Dani Dental Doctor Kit.
Do you handle mouth guard cases from multi-location practices or small DSOs?
Yes. For practices with multiple offices, we can set up location-specific account codes under a single billing relationship. Invoices consolidate by location or roll up to a master account, your choice. Each location can maintain its own standing Rx profile. We currently support DSO groups up to about 50 offices before the workflow model requires a different structure. Contact us to discuss what a multi-location setup looks like for your group specifically.

REQUEST A DOCTOR KIT

Send us a 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.

Request a Doctor KitTalk to a technician