Where Digital Innovation Meets Handcrafted Perfection
At Sentinel Mouthguards, we’re always looking for ways to combine cutting-edge technology with the craftsmanship and care that made us who we are.
3D printing has revolutionized dentistry—and yes, it’s changing how night guards are made. But through years of testing, experimentation, and real-world results, we’ve found something important: while 3D printed teeth models have elevated precision, traditionally fabricated guards still deliver the best overall fit and comfort for our customers.
This guide explains why we use 3D printing for accuracy, but still rely on the human touch to finish each guard to perfection.
🦷 What Exactly Is a 3D Printed Night Guard?
A 3D printed night guard is designed digitally and manufactured using a 3D printer and specialized dental resin instead of being vacuum-formed over a model. The process relies on computer software to simulate fit, thickness, and bite balance.
It sounds perfect in theory—and the technology is advancing fast—but real-world performance still has some catching up to do.
⚙️ How Sentinel Uses 3D Printing (The Hybrid Method)
We’ve found the sweet spot between digital precision and hands-on craftsmanship.
Here’s how it works:
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3D Scanning & Modeling – We begin by digitally scanning the dental impression to create a highly accurate 3D model of your teeth.
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3D Printing the Model – Using advanced dental resin and our Shining Accu printer, we print your teeth model. This gives us a perfect, solid replica to work from.
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Traditional Fabrication by Hand – From there, we form, cut, shape, and polish your custom guard using the traditional thermoforming process we’ve mastered since 2012.
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Fit Check on the Model – Once the guard is shaped, we test it directly on the printed model. We remove and reseat it from various angles to detect even subtle areas of tightness or friction.
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Final Adjustments by Hand – Any spot that “catches” is carefully trimmed, smoothed, and refined—ensuring a truly custom, comfortable fit before it ever leaves our lab.
This hybrid approach combines the digital precision of 3D printing with the artistry and tactile control of traditional craftsmanship—and our customers feel the difference.
🤖 Why Not Fully 3D Print the Guard?
We’ve tested it—extensively.
The short answer: AI and 3D printing are incredible tools, but they can’t yet replicate the nuanced adjustments a skilled technician can make by hand.
Even with intelligent software that lets us fine-tune tightness, thickness, and design details, 3D printed guards can feel slightly rigid or inconsistent compared to a traditionally formed one.
They lack that “human-calibrated fit”—the subtle smoothing, flex testing, and manual adjustments that make a guard feel truly natural in the mouth.
Simply put, AI can predict, but a trained technician can feel.
🧾 3D Printing vs. Traditional Fabrication: What the Data Shows
| Feature | Fully 3D Printed Night Guard | Sentinel’s Hybrid Method (3D Printed Model + Handcrafted Guard) | Traditional (Non-Digital) Fabrication |
|---|---|---|---|
| Precision | Very high digital precision, but may miss subtle anatomical nuances | Ultra-precise 3D model with manual fine-tuning for perfect fit | Depends on manual pouring accuracy and trimming |
| Comfort / Fit | Often slightly rigid; lacks natural flexibility | Custom-refined on printed model for smooth, natural comfort | Variable; depends on technician skill |
| Material Used | Photopolymer resin (rigid or semi-flexible) | Dental resin for the model + thermoform material for the guard | Thermoform plastic over plaster model |
| Customization Control | Software-based (AI predicts tightness, thickness) | Technician adjusts tightness & shape manually for best comfort | Manual adjustment during forming |
| Durability | Improving, but still dependent on resin type | Excellent — proven thermoform strength with digital accuracy | Consistent, but less reproducible |
| Reproducibility | Easy to reprint identical design | Model saved digitally for quick remake if needed | Requires new physical impression |
| Aesthetic Finish | Layer lines and matte surface | Smooth, polished, professional finish | Smooth but less uniform |
| Production Speed | Fastest manufacturing method | Moderate — digital scan + manual shaping | Slowest; fully manual from start to finish |
| Environmental Impact | Lower waste but resin disposal concerns | Balanced — minimal waste, reusable digital files | More waste from plaster and excess material |
| Fit Verification | Software simulated only | Physically verified and adjusted on your printed model | Manual check only (no digital backup) |
| Overall Result | Good digital accuracy, limited comfort refinement | Best blend of accuracy, comfort, and customization | Reliable but less scalable or precise |
🧩 The Benefits of 3D Printing the Model (Not the Guard)
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Unmatched Accuracy: Each printed model captures your unique anatomy down to fractions of a millimeter.
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Reproducibility: If you ever need a replacement, your digital model is securely stored for quick remakes—no new impression required.
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Cleaner Workflow: The digital design removes traditional plaster mess, producing a cleaner, more sustainable process.
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Perfect Partner for Handcrafting: The rigid printed model gives our technicians an ideal platform to perform manual fit checks and micro-adjustments.
This synergy of new and old-world methods ensures the best of both: digital precision with handcrafted comfort.
🧠 The Future of 3D Printed Night Guards
We have no doubt that 3D printed night guards will soon rival—and possibly surpass—traditional ones.
As resin materials advance and software becomes more intuitive, AI-driven customization will continue to close the gap between “digitally perfect” and “human perfect.”
At Sentinel, we’re already at the forefront of this evolution, continuously testing new materials and design software so that when the technology truly reaches parity, we’ll be ready to deliver the next generation of fully 3D printed guards—without compromising comfort or quality.
Until then, our hybrid approach remains the gold standard.
💚 Why Sentinel’s Process Produces the Best Fit
Because we never stop at “good enough.”
Every guard that leaves our lab has been:
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Digitally scanned and 3D printed for precision.
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Hand-shaped and refined for comfort.
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Fit-tested and adjusted on your exact model.
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Polished, sanitized, and finished by a real person who cares.
🔁 Easy Reordering—No New Impression Needed
Once your dental impression has been scanned and converted into a precise 3D model, it’s securely saved in our system indefinitely. That means if you ever need a replacement or want to order a backup guard, there’s no need to take another impression.
We can simply pull up your digital file, print your model again, and craft a fresh, perfectly fitting guard using the same custom specifications.
💚 Fast, accurate, and hassle-free—because your comfort shouldn’t have to wait.
That’s the Sentinel difference: technology that supports craftsmanship—not replaces it.
🛒 Ready to Experience the Best of Both Worlds?
Order your custom night guard today and experience the next generation of comfort and precision.