Pressing Stages
The pressing stages form the core structure of the Hundredjack mouthguard.
This process uses sequential thermoforming to create a multi-layered product that combines structural strength, customization, and protective encapsulation.
Small deviations in temperature, timing, or pressure lead to delamination, weak adhesion, or defective fit. For this reason, pressing must be performed with certified Dreve materials and calibrated thermoforming machines only.
Objectives
Build a multi-layer mouthguard through controlled thermoforming.
Ensure strong adhesion between layers (no bubbles, voids, or delamination).
Encapsulate patient-selected graphics without compromising durability.
Responsibilities
Pressing Technician: Execute all pressing cycles and record parameters.
QC Officer: Verify layer adhesion after each press.
Hundredjack SaaS: Store calibration logs, material batch numbers, and timestamps.
Procedure
General Parameters (Apply to All Presses)
Temperature: ~130 °C (validated range: 128–132 °C).
Heating Time: 1:50–2:20 min (longer = bubbles, shorter = poor flow).
Cooling: must occur with model mounted on platform.
Logs: record material batch number, machine ID, technician ID in SaaS.
1. First Press — Base Layer
Objective: Create the structural foundation.
Preheat Dreve base sheet in thermoformer.
Position model centrally; start vacuum/pressure cycle.
Allow full adaptation, then cool 8 minutes before removal.
Trim excess to form initial “glove”: canine-to-canine, partial premolar coverage.
Reduce palatal extension up to cingulum for comfort.
Perforate base with fine needle to release trapped air bubbles.
Checks
Uniform thickness.
No voids or air gaps.
Strong adaptation around anterior and premolar teeth.
2. Second Press — Customization Layer
Objective: Add patient’s chosen colors and graphics.
Place colored Dreve sheet on base.
Apply graphic foil ≥3 mm from borders (to prevent delamination).
Thermoform; allow 10 minutes cooling before removal.
Verify adhesion between base and customization layer.
Trim palatal and occlusal areas for occlusion comfort.
Extend coverage to first molar (tooth 6).
Perforate with fine needle if micro-bubbles detected.
Checks
Layers bonded seamlessly.
Graphic intact: no wrinkles, displacement, or bubbling.
Proper occlusal clearance maintained.
3. Third Press — Protective Layer
Objective: Encapsulate and reinforce design.
Place transparent Dreve sheet over customized shell.
Thermoform; allow 12 minutes cooling before removal.
Inspect encapsulation for full coverage.
Ensure graphic and color layers are fully sealed.
Checks
Outer shell transparent, smooth, bubble-free.
No peeling or incomplete bonding.
Removal requires significant force → proof of strong adhesion.
Checks & Controls (All Stages)
Record material batch number, press ID, and technician signature in SaaS.
Calibration log of thermoformer linked to case.
QC Officer validates layer adhesion at each step before next press.
Output
At the end of pressing:
A multi-layered mouthguard shell exists, combining base strength, personalization, and protective sealing.
Product is ready for Finishing & Quality Control.
Compliance Notes
Non-Dreve sheets = automatic rejection.
Missing machine calibration log = non-conformity.
Delamination, bubbles >2 mm, or incomplete encapsulation = mandatory remake.