3D Printing Occlusal Guards, Night Guards, and Splints

Data Capturing 

 

In order to print the dental model, the patient’s impression must first be captured digitally. This can be accomplished with intraoral impression scanners, desktop impression/model scanners, or via CBCT impression/model scanners. ​

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Scan Integrity Considerations

 

Intraoral scan should not have problematic areas that can lead to errors in the printed appliance or patient discomfort

Occlusion is unclear or scan has bubbles:

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Scan has scraps:

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Scan is coincident and contains distortion:

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Scan is incomplete and missing data/sections:

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Design and Treatment Planning

Out of Office Occlusal Guard Design


SprintRay Cloud Design helps and provides Occlusal Guard Design, where you can upload patient’s scan files and your prescription. Once you receive the STL file of the designed occlusal guard from SprintRay Cloud Design, printing can proceed

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In-Office Designing Occlusal Guard Design


This is done in a Splint CAD software. SprintRay Software allows you to choose a splint software that best meets your clinical needs. Our software accepts any design file formatted in STL, which means you can use whichever software you are most comfortable with: 3Shape Splint Studio, Exocad, Magics, D3splint. Once the scans are imported to the design software:

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Note: Proper Software Settings Required! Occlusal guards should always have a minimum thickness of at least 2.5mm for best results.


Follow the instructions for SprintRay Splint material and choose/provide proper settings in the software. Continue to complete the occlusal guard design. An embossed annotation on the model can help to keep track of your prints/patients.

 

 


Printing - Special Considerations

IFU for the occlusal guard resin in use should always be followed for best results.

 

As a general recommendation, it is best to angle the model on print platform so that the intaglio surface is facing up, and the occlusal plane makes an angulation of 20-30° to the print platform. The anterior part of the design should be closer to print platform than the posterior.

 

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Post processing


Models should always be post processed per the recommendation in the resin Instructions For Use (IFU).

 

  • For SprintRay NightGuard resins, Isopropyl Alcohol with a purity of 91% or higher is required for the washing process, per the FDA.
  • If cleaning more than 2 or 3 models in the Pro Wash/Dry, longer wash and dry times may be necessary for best results.
  • Always ensure models are completely clean before post curing in the Pro Cure units, and always select the correct profile for the resin being used.

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Appliance Preparation for patient delivery


Support Removal

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Once the post curing is completed, we need to remove all the supports by using a flush cutter. Try to cut as close as possible to the appliance surface to minimize the smoothening and polishing procedure.

 

Smooth the Surgical Guide

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At this step, we use a fine Scotch-Brite™/ Fuzzies™ polishing wheel to grind down the remaining knobs from the support-removal step and smooth out the surface of the appliance. The polishing wheels are used at a low speed (about 10,000 to 12,000 rpm).

The last steps in this workflow are delivering the occlusal guard to the patient for fitment and final polishing. During this step, make sure the appliance is seated completely on the teeth with proper retention, and that it is completely polished before delivery to the patient.

 

Cleaning and Disinfecting

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Use dish soap and a soft toothbrush to clean the appliance before trying it in the patient's mouth

 

Soaking

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Soak the appliance in a bowl of warm water for about 20-25 seconds. Make sure the water temperature does not exceed 50°C/122°F.

 

Try-in and Adjustment

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Seat the printed occlusal guard on the patient's teeth and let them try out the appliance. Use an articulating paper to make any adjustments if needed for the proper contact between the occlusal guard and opposing teeth

 

Pre-Polish

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Use a muslin polishing wheel and pumice with firm and consistent pressure to reach all the areas of the appliance. Make sure the wheel and pumice are wet enough, and the pumice is flowable. Once done, rinse the guard with water to remove pumice residue.

 

Polish

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Start with a fresh muslin wheel and Tripoli polishing compound. Use firm and constant pressure, reaching all the areas of the appliance. Re-apply the Tripoli compound, but this time use light pressure. Once done, rinse the guard with water to remove Tripoli compound residue.

 

High-Shine

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Use a fresh muslin wheel and Hatho™ Beige polishing compound, with firm and consistent pressure, reaching all the areas of the appliance. Make sure to achieve a uniform shine on the appliance. Once done, rinse the guard with water to remove high-shine compound residue.

 

High-Gloss (Optional)

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Use a cotton buff wheel and Hatho Pink polishing compound with consistent pressure, reaching all the areas of the appliance until you get a “mirror finish”.

 

Cleaning the Occlusal Guard

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Use dish soap and a soft toothbrush to clean the appliance before trying it in patient’s mouth.

 

Packing

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Pack the finished occlusal guard in a container that has the patient's name/file number, and then deliver it to the patient. Provide the patient with instructions on how to use and clean the occlusal guard.

 

We can help with that!

If you're experiencing difficulties or have questions about any of your SprintRay products, submit a support ticket or contact us at 800-914-8004

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