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

sleep apnea mouth guard

Oral appliance therapy starts with a device that actually fits. Dani Dental fabricates custom sleep apnea mouth guards using digital impressions and thermoplastic milling, with a 5-business-day turnaround from scan receipt.

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

Every sleep apnea mouth guard case opens with a digital intake review. The referring dentist submits an intraoral scan (STL or PLY), a protrusive bite record, and the target mandibular advancement range. Our technician reviews the scan for occlusal contacts, inter-arch spacing, and any edge-case anatomy before a single milling path runs. If the scan quality or bite record raises a fit question, the technician calls the practice directly, same day. Appliance design runs inside our certified CAD environment using appliance-specific design modules, not repurposed crown-and-bridge tooling. The distinction matters. Crown-and-bridge CAD parameterizes tight margins; sleep appliance CAD parameterizes hinge articulation, protrusion stops, and lateral freedom. We maintain separate design templates for monobloc, twin-block, and EMA-style configurations, each pre-validated against AASM oral appliance therapy guidelines. Milling uses medical-grade thermoplastic pucks selected by appliance type. Monobloc devices mill from a single dual-layer puck; twin-block constructions use paired single-layer blanks joined at post-processing. Every milled appliance goes through a manual fit check on the printed model before shipping, not an automated QC scan alone. The technician who designed the case performs the fit check. That accountability loop is how we hold the <2.5% remake rate. Shipping uses a tracked courier with foam-insert packaging sized for appliances, not the generic lab mailer that lets a device rattle. Every box includes a brief case summary sheet listing the protrusion setting used, the advancement range designed for, and the direct phone extension of the fabricating technician. If the patient returns for a titration adjustment, the dentist calls that number and reaches the person who built the device, not a general queue. For DSO accounts managing sleep apnea protocols across multiple offices, we offer a standardized intake form, a shared case portal for tracking open appliance orders, and a monthly QC summary. Billing runs per-appliance with no per-location account fee. The operational lift of coordinating across 10 to 30 offices is handled on our side, not yours.

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 sleep apnea mouth guard are being detailed and will appear here.

MATERIALS

What goes in the mouth.

The material options for sleep apnea 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 sleep apnea 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 sleep apnea mouth guard

What file formats does Dani Dental accept for sleep appliance cases?
We accept STL and PLY files from all major intraoral scanner platforms, including iTero, 3Shape TRIOS, Medit, and Carestream. Physical impressions are accepted for practices that have not yet moved to digital, but digital scans produce better fit outcomes on sleep appliances because a protrusive bite registration in the scanner captures 3D contact data that a PVS impression cannot. We recommend digital submission for any titratable device.
How do you determine the starting mandibular advancement position?
We fabricate to the protrusive bite record submitted with the case. We do not set advancement position independently. The dentist or sleep medicine physician determines the target range based on patient anatomy, AHI severity, and comfort tolerance. Our design template then builds the appliance to that specification with a clear notation of the protrusion setting on the case summary sheet that ships with the device.
What is the turnaround time for a sleep apnea mouth guard?
Five business days from confirmed scan receipt. Rush fabrication (3 business days) is available on request, subject to current production load. Rush cases carry a 30% surcharge. The clock starts when we confirm the scan is complete and the bite record is on file, not when the email arrives. Incomplete submissions pause the clock until the missing item is received.
Which appliance design is right for my patient cases?
That is a clinical decision, not a lab decision, and we are careful about that boundary. What we can offer: if you are managing patients with significant vertical opening requirements or limited incisor protrusion range, a twin-block configuration typically gives more mechanical latitude than a monobloc. If you want the simplest titration protocol and a thinner profile, the EMA-style is the most common choice among practices we work with. We are happy to discuss case specifics with you before you submit.
Can I submit sleep appliance cases alongside restorative crown-and-bridge work in the same shipment?
Yes. Cases ship together and bill separately by category. Sleep appliance cases route to the appliance team on our floor; crown-and-bridge cases route to the restorative team. Each has its own technician, timeline, and QC checkpoint. They share a courier box but they do not share a production queue. You receive one invoice with line items per case type.
What happens if the appliance does not fit at delivery?
Call the direct extension on the case summary sheet. The fabricating technician takes the call, reviews what was submitted versus what was built, and determines whether the issue is a scan artifact, a bite record discrepancy, or a fabrication error. Verified fabrication errors remake at no charge within 3 business days. We ask for photos of the fit issue in situ and the returned appliance before we run the remake, so we can correct the root cause rather than repeat it.
Does Dani Dental fabricate MDSA or Herbst-style appliances in addition to the three standard configurations?
Currently our standard catalog covers monobloc, twin-block, and EMA-style devices. Herbst-style and full MDSA fabrication are outside our current production scope. If your case volume in those configurations is significant, contact us and we will evaluate whether adding the design template makes sense for your account. We do not take on cases we cannot build to a consistent standard.
How does Dani Dental handle sleep appliance cases for multi-location DSO accounts?
DSO accounts with 10 to 30 locations receive a shared case portal, standardized intake forms pre-loaded for each office, and a monthly QC summary showing remake rate, turnaround averages, and open cases by location. Billing is consolidated per cycle with per-appliance line items. There is no per-location account fee. Setup takes one onboarding call, typically under 30 minutes.

REQUEST A DOCTOR KIT

Send us a sleep apnea 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.

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