Patent attributes
A method for making a dental appliance is disclosed, including affixing a first blank piece of material to a second blank piece of material forming a combined blank. The first blank piece of material is substantially softer than the second blank piece of material. The combined blank is then placed over a dental cast with the first blank piece of material faces the dental cast, and a dental appliance is formed by using a thermal form suck-down of the combined blank over the dental cast with the first blank piece of material in contact with the teeth of the dental cast. Finally, the dental appliance is removed from the dental cast. The dental appliance can be trimmed while it is on the dental cast or after it is removed. Methods for affixing a first blank piece of material to a second blank piece of material, include laminating the first blank piece of material to the second blank piece of material, bonding the first blank piece of material to the second blank piece of material, and sealing the first blank piece of material to the second blank piece of material. A dental appliance for placement on the teeth of a user is disclosed, including a first layer, created from the first piece of blank material, for direct contact with the teeth of the user, and a second layer, created from the second piece of blank material, affixed over the first layer. The first layer is substantially softer than the second layer.
