How to Create a

Dual Layer Sports Mouthguard

Example shown is with the following products:
• 1st Layer – Drufosoft® Sports Mouthguard Material - .120” (3mm) Blue
• 2nd Layer – Drufosoft® Sports Mouthguard Material - .120” (3mm) Clear

Note: When layering plastics, approximately 40% shrinkage occurs. This example
creates a 3.5 to 4.0mm Sports Mouthguard. Doctor chooses the appropriate thickness
for each case based on patient, dental history and level of sport.

1ST LAYER

Start by turning the Drufomat Scan on;

1 the switch is located on the back left side
1
of the machine. There is no wait time for
your Drufomat Scan to heat up.

Lift the tension ring off the plate

2 reception on the left side of the
Drufomat, and place the 1st layer
plastic — Drufosoft® Sports Mouthguard
Material - .120” (3mm) Blue — in the
plastic holding arm.

Place the tension ring into the round

3 pegs and secure over the plastic.

Place the model in the center of the

4 base of the machine. NOTE: To avoid
broken models, residue from stone and
distortions, spray model with Trim-Rite®
Release Agent.
2a 2b

3a 3b 4

10
1ST LAYER continued
Align plastic and heating element over
5 the model.

Scan the barcode for Drufosoft® Sports

6 Mouthguard Material - .120” (3mm) from
the Essix® Plastics Guide.

Screen will read heating time 1:50 and

7 cooling time 6:00.

8 Press the OK button.

The heat indicator lights will shine red at

9 the base of the Drufomat Scan indicating
the heating process has started.
5 6

7 8 9

Once the heat time has expired, you will hear a long beep. Pull the lever on the right side (10b), moving the heating element away from the base
10 of the machine. The lever is spring-loaded, be sure to pull past the point of tension and hold while simultaneously pressing the white button on the
left side (10a) of the Drufomat Scan. Once the pressure bar on the screen rises to level 2, you can release both the lever and the white button at
the same time.

10a 10 10b

11
 1ST LAYER continued
The cooling process has started. Once the timer counts down to zero,
11 you will hear a short beep indicating that the cooling process is complete.
Release both valves on the front of the machine. Releasing excess air will
ensure adaptation to the model. Be sure to tighten both valves back before
your next appliance.

Press and hold the white button on the left side of the Drufomat Scan as the
12 air releases and the chamber lifts from the model.

13 Remove the tension ring from the plastic.

11

12 13a 13b

TRIMMING THE 1ST LAYER — Allow the appliance to cool to room temperature before proceeding.
Use your heat knife to trim the plastic.
1 Be sure to trim to the vestibular borders
and the frenum. Use an alcohol wipe to
wipe down the first layer removing any
oils and glove powder. DO NOT POLISH
THE FIRST LAYER, THIS WILL CAUSE
DELAMINATION.

If a logo or sticker is wanted, place

2 the sticker on the first layer of the
mouthguard now. Use stickers or glue to
adhere customized logos to the plastic.
1a 1b 1c

2 1d 1e 1f

12
2ND LAYER
Place model with the distal end close to the rear of the base plate. This allows
1 more coverage of the 2nd layer of the plastic to cover the anteriors.

Lift the tension ring off the plate reception on the left side of the Drufomat, and
2 place the 2nd layer plastic — Drufosoft® Sports Mouthguard Material - .120”
(3mm) Clear — in the plastic holding arm and secure the tension ring into the
round pegs.
1

2a 2b 2c

3 Align plastic and heating element over the model.

Scan the barcode for Drufosoft® Sports Mouthguard Material - .120” (3mm) - 2nd
4 layer from the Essix® Plastics Guide.
Be sure to scan the 2nd layer barcode for the Drufosoft® Sports Mouthguard
Material - .120” (3mm); the screen should read 3:00 heat, 8:00 cool.
If you do not scan in the proper barcode, the two layers will not laminate.

5 Press the OK button.

4b

3 4a 5

13
 2ND LAYER continued
The heat indicator lights will shine red at the base of the Drufomat Scan indicating the
6 heating process has started.

Once the heat time has expired, you will hear a long beep. Pull the lever on the right side
7 (7b), moving the heating element away from the base of the machine. The lever is spring-
loaded, be sure to pull past the point of tension and hold while simultaneously pressing the
white button on the left side (7a) of the Drufomat Scan. Once the pressure bar on the screen
rises to level 2, you can release both the lever and the white button at the same time.

7a 7 7b

The cooling process has started. Once the timer counts down to zero,
8 you will hear a short beep indicating that the cooling process is complete.
Release both valves on the front of the machine. Releasing excess air will
ensure adaptation to the model. Be sure to tighten both valves back before
your next appliance.

Press and hold the white button on the left side of the Drufomat Scan as the
9 air releases and the chamber lifts from the model.

8 10 Remove the tension ring from the plastic.

9 10a 10b

14
TRIMMING AND POLISHING THE 2ND LAYER —
Allow the appliance to cool to room temperature before proceeding.

Trim using the heat

1 knife as used previously
with the
first layer.

1a 1b 1c

Use the mouthguard

2 trimming bur to remove
bulk of rough material.

2a 2b 2c

Place the mouthguard

3 back on the model. Use
the mouthguard trimming
bur to file down the lingual
pallet area for patient
comfort and speech

Use the fine polishing

brush for a smooth finish.
3a 3b 3c 4

4c
4a 4b Materials used for Sports Mouthguard:
• Drufomat Scan (#3300)
• Drufosoft® Sports Mouthguard Material -
.120” (3mm) Blue (#4249-5)
Once the polishing is complete, the mouthguard should be smooth but dull in luster. To • Drufosoft® Sports Mouthguard Material -
5 bring a shine to the mouthguard, swipe with finishing liquid using a cotton/paper towel or .120” (3mm) Clear (#4249)
• Trim-Rite® Release Agent (#21004)
use the blazer torch and lightly pass the flame over the mouthguard. The mouthguard is
• Precision Electric Heat Knife (#88550)
now complete and ready for occlusal adjustment if necessary.
• Sports Mouthguard Trimming Bur (#MGTB-1)
• Polishing Brushes Combo Pack (#1898C)
• Finishing Liquid (#4466N)
• Butane-Powered Microtorch (#MT001)

15
Get to Know Your Drufomat Scan
Pressure Thermoforming Machine
1.800.883.8733 essix.com
Dentsply International Raintree Essix
7290 26th Court East
Sarasota, FL 34243

©2017 Dentsply Sirona. All Rights Reserved. Dreve and Drufomat are not trademarks of Dentsply Sirona.
RTE-221-17 Rev. 01 Issued 09/17 #MK-3300WK-HOWTOGUIDE