Manufacturing Process

Posted on September 17, 2011 at 12:37 pm by scott No Comment

I can say that without a doubt we are the premier mouth guard company in the world. We started from manufacturing guards on a vacuum forming machine and then graduated to the thermoforming process. I believe that it is very important for customers and potential buyers to understand how a custom mouth guard is manufactured and what their actually paying for. Every mouth guard we make is completely custom starting from the first layer. I want this particular blog to be understandable for everyone that reads it so I will not be using a lot of dental words that no one understands to explain the process. This is meant to inform you on the process the many companies are using and how a Python Guard defers from these processes. I recently attended a sports dentistry convention where they showed dentists how to manufacture custom mouth guards. The dentist giving the instruction has lead the Sports Dental Association for many years and is highly regarded in the field of sports dentistry. The dentist were presented a mold of the mouth and showed how to manufacture a guard without any graphics. The dentists applied two layers of mouth guard 3mm thick and then trimmed the edges of the mouth guard. This is the method they are teaching dentists using a thermoform machine but many dentists only use a vacuum form machine which is only 1 layer thick and the thickness is only able to be controlled by the size of the material that is used. The process took approximately 30 minutes to perform and costs you around $300.00. The problems that I saw with how they manufactured their mouth guards were mainly pertaining to thickness. The dentists have a large amount of clinical knowledge but lacked the practical knowledge required to make a useable custom mouth guard. If you’ve never used a custom mouth guard it’s very difficult to understand where thickness is needed and where thickness is a hindrance.

Python Guards starts with 2mm material that reduces itself to 1mm after heating. Instead of putting another 2mm material on top we start hand building just the outside of the guard (outside of teeth) until we reach the desired thickness while following the shape of the customer’s mouth. Once we reach the thickness desired we grind the guard until completely smooth. Then we place the colored material on top of the built up guard so that it seals the over the edges of the first layer. We then place the graphic on top followed by 2 mm clear material. The process we use is not followed by any other mouth guard company because it takes approximately 4 hours to manufacture 1 mouth guard and costs around $95.00. The thickness on the inside of the guard is around 2mm thick but most importantly it fits comfortably because we start with a thin layer. Because I have the clinical and practical knowledge from training as a fighter I understand exactly where mouth guards can be uncomfortable and overly thick but just as important I understand what is comfortable. I use MMA as an example because it is a sport that requires a huge amount of cardio but this same technique is used for all mouth guards manufactured by Python Guards. Dentists may not like what I’ve stated but it’s time for clients and customers to know what their purchasing and how mouth guards defer from manufacturer to manufacturer. My goal is to educate people thinking about purchasing mouth guards not sell them on how good Python’s custom mouth guards are. As long as individuals know exactly what their buying then I’ve done my job.

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