Mouth Guard - PlaySafe Mouthguards - Mouth Guard Dental Lab

Clinical dentistry by Michael C. DiTolla, DDS, FAGD

Introduction

How do you make a laminated PlaySafe mouthguard with a helmet strap or decal? Let's examine the technique for fabricating a custom sports mouthguard using the ERKODENT® thermoforming system.

Figure #1
Embed the model into the granules in such a way that the higher vestibule area remains visible.
Figure #2

Isolate the model with Isolac.
Figure #3

Alternatively, you may use the universal UZF spacer.
Figure #4

Cover the granules with the covering template.
Figure #5

Place the transparent Erkoflex foil into the foil frame ring. Secure the foil cover ring over the foil frame ring.
Figure #6

Next, join the form pot with the foil frame.
Figure #7

Enter 1 min., 25 sec. (01:25) into the timer switch.
Figure #8

Press the confirmation switch. This begins the preheating cycle.
Figure #9

Once the preheating cycle is complete, an audible signal is heard. Bring the thermoforming assembly directly under the heater.
Figure #10

When heating is complete, an acoustic signal sounds. The display shows "0:00" and the control light goes out.
Figure #11

Using the handle, quickly move the thermoforming assembly to the right, along the fence in the back until it stops.
Figure #12

Activate the cylinder by turning the rotating knob to the right.
Figure #13

After heating, cooling takes place for 1 min., 30 sec. (01:30). Upon completion of the cooling cycle, an acoustic signal sounds. Turn the rotating knob to the left to move the cylinder upward. Then, move the rotating knob back to zero.
Figure #14

Take out the thermoforming assembly and release the foil cover ring.
Figure #15

Remove the model together with the foil.
Figure #16

After the disc has completely cooled, remove from the model.
Figure #17

Trim with the special scissors, making sure to retain as much of the alveolar ridge, vestibular and palatal areas as possible.
Figure #18

Place the disc back onto the model.
Figure #19

Now embed the model back into the granules, leaving the vestibule area exposed.
Figure #20

Then place the cover template over the granules.
Figure #21

Next, use a degreaser to eliminate all hand oils and debris from the first Erkoflex layer.
Figure #22

Using the sponge enclosed with the degreaser, carefully wipe the surface of the Erkoflex layer.
Figure #23

Use the Erkoflex 4.0 mm sheet to completely degrease the side that will be thermoformed to the model.
Figure #24

Then place the Erkoflex disc into the foil frame and secure the foil frame ring.
Figure #25

Now you will thermoform the Erkoflex 4.0 mm.
Figure #26

To do this, program 2 min., 5 sec. (02:05) into the Erkopress.
Figure #27

After preheating, place the thermoform assembly under the heater. Be sure the assembly completely seats under the heater, until you hear the click and the display begins the heating process.
Figure #28

Then place the thermoforming assembly under the heater and turn the knob to the right. This will provide complete lamination of the Erkoform 4.0 mm layer over the Erkoflex 2.0 mm.
Figure #29

After cooling is complete, turn the knob to the left until you hear the pressure release.
Figure #30

When the pressure is released, turn the knob back to the middle position.
Figure #31

Remove from the model only after cooling is complete.
Figure #32

Cut out the mouthguard using the special scissors.
Figure #33

It's important to expose the areas around the frenulums very well, leaving the vestibular area as large as possible.
Figure #34

Cut back the palatal area approximately 2 mm from the gingiva.
Figure #35

The mouthguard should cover the first molar.
Figure #36

If required for boxers, you can also include the second molar.
Figure #37

Place the mouthguard back onto the model to observe where it needs to be trimmed.
Figure #38

Using the Lisko-S disc, carefully work the edges and smooth the areas around the frenulums. Be sure to expose the areas around the frenulums as closely as possible. It's important to consider the athlete's comfort when fabricating the mouthguard.
Figure #39

Bevel the edges of the mouthguard to provide extra comfort for the athlete.
Figure #40

After doing the bulk of the reduction using the Lisko brown disc, switch to the Lisko-S disc to smooth and polish all trimmed areas. Work the entire periphery around the mouthguard so that it is smooth to the touch.
Figure #41

To provide a high shine for the mouthguard and smooth all trimmed areas, use a hot air pen or a flame.
Figure #42

Here we are using the hot air pen, which is important to use when attaching helmet straps. However, do not allow the hot air pen to get too close to the mouthguard, as this will burn the surface.
Figure #43

Continue smoothing all areas until a high gloss is achieved.
Figure #44

You can also use a butane torch. Be careful not to get too close. You don't want to burn the surface.
Figure #45

Now we'll attach a helmet strap. Using the Lisko-S, flatten the edge of the central anterior teeth.
Figure #46

After flattening the edge of the central anterior teeth, wipe with degreaser.
Figure #47

Then, using the hot air pen, make approximately five to eight passes over the mouthguard.
Figure #48

Also, make five to eight passes over the helmet strap.
Figure #49

Quickly introduce the strap into the desired location on the mouthguard.
Figure #50

It's important to apply pressure during this time, to ensure that the two materials completely laminate.
Figure #51

Once the area is cool, the mouthstrap should be tightly positioned.
Figure #52

Next, remove the UZF spacer from the internal fit and place back on the model.
Figure #53

Closely observe the mouthguard to make sure all areas that were trimmed are smooth and glossy.
Figure #54

When we make the laminated mouthguard for a decal, we basically reverse the process by using the Erkoflex 4.0 mm sheet first.
Figure #55

Thermoform this layer just as you would in the other technique and cut out with the special scissors.
Figure #56

Using the Lisko brown disc, flatten the entire periphery of the mouthguard.
Figure #57

Make sure that the Erkoflex 4.0 mm layer is contoured in the area around the periphery of the frenulums, and bevel the edges completely.
Figure #58

It's key to bevel the edges well so that the mouthguard will be comfortable for the athelete.
Figure #59

Be sure that the entire area of the mouthguard is completely degreased, using the sponge ensure complete lamination.
Figure #60

Next, carefully trim the decal.
Figure #61

After that, heat the area of the Erkoflex 4.0 mm.
Figure #62

Then carefully place the decal on the area of the mouthguard.
Figure #63

Embed the model into the granules and place the cover template.
Figure #64

Now we will use the Erkoflex 2.0 mm transparent sheet. Be sure to degrease both sides of this layer.
Figure #65

Position into the thermoforming assembly and thermoform as usual.
Figure #66

After the mouthguard is cool, remove from the model. Using the special scissors, trim around the area of the mouthguard.
Figure #67

Trim the palatal area approximately 2 mm from the gingival margin.
Figure #68

Then use the Lisko-S disc to polish and smooth the edge of the mouthguard.
Figure #69

Begin by flattening completely and ensuring the frenulum areas are free.
Figure #70

Once it is entirely smoothed with the Lisko-S disc, remove the universal spacer.
Figure #71

Position the mouthguard back on the model, then polish all trimmed areas with a hot air pen or a flame.
Figure #72

This completes the process of fabricating a mouthguard with a decal.

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