Orthodontic Appliance Fabrication Requirements


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Fabrication Guidelines

To provide you with the highest standards of quality and service, we ask
that you follow our appliance fabrication requirements. Please feel free to
call Laboratory Customer Service at 800.828.7626 (U.S. & Canada) or 716.871.1161 (Worldwide) Monday - Friday 8:00a.m. to 5:00p.m. (EST), or email us for further technical assistance.
View/download fabrication guidelines by individual
appliance family:
Elastodontics and Positioners

Functional Appliances
(Twin Block, Herbst®*, Bionator/Orthopedic Correctors, Activator,
Function Regulator - Fränkel)
*Herbst is a registered trademark of Dentaurum, Inc.

Metal Appliances

Retainer and Aligners
(Retainer & Active Plate, Spring Aligner, Inman Aligner, Invisible Aligner)

Sleep Apnea Appliances
(Herbst® Sleep, Klearway, NAPA, Elastomeric)

(Digital Occlusal Splint, Standard Occlusal Splint)

Important to every case…

 Prescriptions: Please provide a complete and signed Rx with every case. Click here to access Rx forms and shipping labels.

  Accurate impressions with any type of impression material are acceptable
  Impressions must adequately reflect all relevant anatomy
  Impression material must not be separating from the impression tray
  Consider pouring your models right away if your impressions are 
    moisture, temperature, or time sensitive
  Impressions sensitive to moisture content should be wrapped in a damp
    paper towel and placed in a sealed plastic bag if models are not poured
  Only metal impression trays and those with VPS impression material will be
•  The nature of impression materials currently on the market may contribute
    to common model problems encountered in the laboratory. Have you
    encountered porosity (bubbles, voids) or poor surface quality? Plaster or
    stone mixes are water based and they interact with impression surfaces in 
    a water-like manner. Liquids placed on solid surfaces will be either
    attracted to, or repelled from that surface in varying degrees. Please be
    aware when selecting impression material if it is hydrophilic or hydrophobic.

     Hydrophilic: is attracted to, or can be wetted by water.
     Hydrophobic: is when liquid is repelled or fails to bond with liquids.
     Vinyl poly siloxane (VPS) options can be hydrophilic or hydrophobic.
        Alginate is hydrophilic.

•  There are advantages and disadvantages to these impression options but
    there are products on the market to help reduce the disadvantages.
    Surfactants and debubblizer sprays can be used to lower surface tension
    between surfaces making the impression material more hydrophilic and
    assure a better impression result.

•  Great Lakes carries ACU-flow™ a VPS impression material which is
    hydrophilic and requires NO surfactant spray for surface tension reduction,
    eliminating bubble formation. Surfactants must be used properly and excess
    surfactant should not be allowed to pool in the cusp tips. This can cause
    loose, sandy-like cusp tips. Excess surfactant needs to be blown out leaving
    a wet look only before pouring.

Models:   Plaster or stone models are acceptable. Generally, the durability of stone
    is preferred.
  Models should be reasonably trimmed, yet sufficiently thick for strength
  No horseshoe-shaped models; Models should have a base of at least 7mm
    in the thinnest area.
  Bases will be added as necessary (for an additional fee) to models without
    bases or those lacking adequate base thickness or strength.
  Please indicate if your model must be duplicated as work models may get
    damaged during the appliance fabrication process.
Bite Records:   Please package bite registrations carefully.
  Bite records must not be left between models for shipment to the lab.
  Dedicated packaging should be considered for brittle materials such as
    Delar wax.
  Please identify the nature and the intent of each bite record, if more than
    one is being supplied.
  Please consider mounting the maxillary model, before sending it to the
    lab, for those cases requiring mounting. Sending items such as facebows,
    bite forks, and mounting jigs through the mail often results in unreliable
Articulators: We use the following articulators and their accessories in our laboratory:

•  SAM® 1, SAM® 2, SAM® 3
  Whip Mix
  Stratos 200

NOTE:  Great Lakes can only fabricate Digital Splints/Deprogrammers for models mounted with the following compatible articulators -

      SAM® 1, SAM® 2, SAM® 3
      Hanau™ Modular

Models mounted with other articulators can only be used for fabricating conventional splints/deprogrammers.

•  Please consider that fully mounted models may not transfer perfectly from
   your articulator to the one in our lab.

Materials and Components:   (*) Biocryl Resin: cold cure acrylic - MMA (methyl methacrylate)
  Clear Biocryl: thermo-formable PETG (polyethylene terephthalate glycol)
  Colored/Patterned Biocryl: thermo formable PVC (polyvinyl chloride)
  Splint Biocryl: thermo-formable PETG
  Triad® (Visible light cure)
  Mouthguard Material: thermo-formable EVA (ethylene vinyl acetate)
  (*) Duraloy: cobalt/chromium alloy
  (*) Stainless steel: chromium/nickel alloy
  (*) NiTi: nickel titanium alloy
  TMA: titanium/molybdenum alloy
  Menzanium: nickel-free stainless alloy
  (*) Silver solder
     (*) Material is potentially allergy causing in sensitive patients.