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

mouthguards

Dani Dental fabricates custom mouthguards, occlusal splints, and athletic guards using 3-axis digital design and pressure-formed or hard/soft laminated materials, with a standard turnaround of 5 business days. Dentists across the Phoenix metro have ordered over 300 custom guar...

  • 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 begins with a digital scan intake or PVS impression pour-up, depending on what the referring practice sends. We run each arch through our in-house CAD review before any material touches the pressure-former or mill. That step catches undercuts, inadequate retention zones, and occlusal conflicts before they become remakes. It takes an extra 30 minutes on our end. It saves the practice a second appointment on theirs. For occlusal splints and bruxism guards, we use Zahn Dental's Drufomat pressure-forming system with BPA-free EVA and hard acrylic sheet stock. The Drufomat workflow gives us consistent wall thickness across the arch, which translates to even occlusal contact and predictable seating. Anterior guidance ramps on Michigan-style splints are shaped by the technician on the case, not delegated to a finishing runner. The technician's direct line ships with every case. Athletic mouthguards follow a separate protocol. We laminate a soft inner layer for impact absorption to a firmer outer shell, pressure-formed in two stages. The result is a dual-laminate guard that holds its shape under repeated impact while staying comfortable enough that athletes actually wear it. Thickness is specified per arch, documented on the case ticket, and repeatable on reorder. For practices sending intraoral scan files, we accept STL and PLY formats from all major scanner platforms including iTero, 3Shape TRIOS, and Carestream. The digital model is articulated virtually before fabrication begins. Practices can email or call with adjustment notes before we close the case; the named technician responds within four business hours. Quality check at Dani Dental is a physical step, not a checkbox. Each finished appliance is seated on the poured model, checked for even contact with articulating film, inspected for surface finish and edge polish, then photographed for the case record. That photo documentation protects the practice and gives us a reference if the patient returns with a seating complaint.

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 mouthguards are being detailed and will appear here.

MATERIALS

What goes in the mouth.

The material options for mouthguards, 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 mouthguards 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 mouthguards

What file or impression formats does Dani Dental accept for mouthguard cases?
We accept intraoral scan exports in STL or PLY format from iTero, 3Shape TRIOS, Carestream, and most other major platforms. If your practice is not yet scanning, PVS impressions work fine. We pour the model in-house and proceed from there. Either path reaches the same digital CAD review step before fabrication begins.
How long does a custom mouthguard or occlusal splint take to fabricate?
Standard turnaround is 5 business days from the day we receive a complete scan or approved model. Rush requests for 3-business-day delivery are available for most appliance types. Call the lab before submitting a rush case so we can confirm the opening in the production schedule. Scheduling a rush case online without confirmation can delay it rather than speed it up.
What materials are available for occlusal splints?
We fabricate in three configurations: hard acrylic (Michigan-style anterior guidance or full-coverage flat plane), soft pressure-formed EVA, and dual-laminate hard/soft for patients who need a firmer biting surface with a softer tissue-facing layer. Material selection depends on the clinical indication. If you are uncertain, send the case with a note and the technician on the case will call you before cutting material.
Does Dani Dental fabricate athletic mouthguards for team orders?
Yes. We handle single-patient athletic guard orders for practices and multi-unit team orders. Team orders require a print or scan for each athlete. Lead time scales with volume: orders of 10 or fewer guards ship on the standard 5-day cycle; orders above 10 units should be discussed with the lab at least 10 business days before the required ship date.
What is the remake policy if a mouthguard does not seat correctly?
If the guard does not seat on the model it was fabricated from, we remake it at no charge. If the problem is a change in the patient's dentition after fabrication, we work out a resolution case by case. Our remake rate on mouthguard and splint cases ran below 2% across 2024. When a remake does happen, the original technician handles the correction, not a different person starting fresh.
Can I specify occlusal contact design for a Michigan-style splint?
Yes. You can specify centric stops, anterior guidance angle, and canine rise on the prescription form. If you have a specific protocol from your residency or a named author's technique, note it on the case ticket. The technician will follow it or call you within four business hours if there is a design conflict with the patient's model that needs discussion before proceeding.
How does Dani Dental handle cases from practices that are just starting to scan?
We have onboarded practices from impression-only workflows into scanning in as little as 2-3 cases. Most scanners that export STL work with our intake system without any configuration on the practice side. We can walk your front desk or assistant through the file submission process on a 15-minute call. There is no setup fee for scan-based mouthguard submission.

REQUEST A DOCTOR KIT

Send us a mouthguards 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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