The finishing and quality control stage transforms the thermoformed shell into a patient-ready medical-adjacent product.
This stage ensures comfort, durability, and safety. Poor finishing or weak QC can compromise retention, create irritation, or allow defective products to reach patients.
Trim and polish the mouthguard for comfort and fit.
Verify thickness, adhesion, and aesthetics meet standards.
Reject defective or non-conforming products before packaging.
Finishing Technician: Perform trimming, polishing, and shaping.
QC Officer (or Lead Technician): Approve or reject product based on standard checklist.
Hundredjack SaaS: Store QC checklist, technician ID, rejection logs, and corrective actions.
Use Dreve-certified burs and trimming wheels only.
Remove excess material from palatal and occlusal areas.
Round and smooth all borders to prevent mucosal irritation.
Verify posterior coverage: extend up to first molars unless clinical notes specify otherwise.
Polish edges with approved polishing wheels and compounds.
Ensure inner surface is smooth, free of rough spots or resin residues.
Eliminate micro-fractures from trimming.
The QC Officer must evaluate the finished mouthguard against the following standards:
Fit & Retention
Full adaptation to model without gaps.
Retention strong enough to resist passive dislodgement.
Thickness
Minimum 3 mm in protection zones (anterior + molar areas).
Even thickness across arch.
Structural Integrity
No cracks, tears, or weak points.
No delamination between layers.
Aesthetics
Graphic intact, fully encapsulated, no displacement.
Transparent cover smooth, no fogging, scratches, or air pockets.
A mouthguard must be discarded and remade if:
Layers separate or show incomplete bonding.
Fit visibly distorted or fails retention test.
Thickness below minimum standard.
Bubbles >2 mm in protection zones.
Unapproved materials detected.
Minor bubbles or small cosmetic defects are tolerated only if they do not compromise fit, protection, or patient comfort.
QC checklist completed in SaaS, linked to case file.
QC Officer or Lead Technician must sign digitally.
If rejected:
Document rejection reason (code).
Record corrective action taken.
Reassign case to production for remake.
At the end of this stage:
A patient-ready mouthguard has been trimmed, polished, inspected, and approved.
Only conforming products may proceed to Packaging & Delivery.
Skipped QC or missing digital signature = automatic non-conformity.
Products that leave lab without documented QC = suspension offense.