Thermoforming Instructions
Model Preparation
- The model should be well cured and dry.
- The model should be trimmed to be around 20-25mm high. Try to reduce the height from the gingiva to the model’s base as much as possible so you are thermoforming over the smallest area possible, helping to ensure that the material’s thickness is as uniform as possible throughout the entire appliance.
- Assemble any specialized attachment geometry to the model.
- Fill in any holes or undercuts with blockout material and let dry.
- Suggested: Coat the model with mold release agent to prevent the appliance from sticking to the model and let dry.
Some excellent spray-on model release agents are available from orthodontic product suppliers like Great Lakes Orthodontics. For an inexpensive model release agent, we recommend using a simple 50/50 mixture of water and liquid Ivory soap as a release agent (the same liquid Ivory soap available at many grocery stores). Use a small plastic spray bottle to spray a light coat of the mixture on the model, then use a heat gun or small fan to dry the mixture on the model so it is dry to the touch. It doesn't need
to be bone dry. This solution should make it much easier to remove the model from the formed sheet.
PAM spray-on cooking oil also works well as a release agent, but because it is a mineral oil it can be difficult to clean it off the finished appliance.
Thermoforming Process
- Turn on the thermoformer and enter correct configuration code or heating time for Zendura sheet (see IFU for Zendura material you are thermoforming for recommend configuration code or heating time).
- Thermoform using a pressure of 4 bar (60 psi) or higher. A higher pressure is preferable.
- Preheat the thermoformer before placing the model on the platform.
- Open foil pouch. Place the Zendura sheet on the thermoformer’s thermoforming sheet holder.
- Swing the heating element over the Zendura sheet to begin heating until the sheet is ready to be
formed. The sheet is ready to be formed when it sags 12mm to 20mm.
Instructions for Use
Detailed and material-specific documentation: