Hard Soft Night Guard | Dual-Laminate Occlusal Guard

Custom-fabricated dual-laminate occlusal guard, thermoformed, soft-inside / hard-outside. Made to your Rx from your impression or intraoral scan. Adult maxillary or mandibular, full arch. Standard 5–7 business days.

• Design: 2-layer laminate — soft intaglio + hard occlusal
• Total thickness: 2.0 – 4.0 mm (Rx-driven)
• Materials: PU / EVA / TPU (soft) · Copolyester / PMMA / PETG (hard)
• Process: Pressure thermoforming, uniform heat and hold-pressure cool-down
• Standard turnaround: 5–7 business days, ex works. Rush 2–3 days available.
• Warranty: 90 days against fabrication defects (fit, retention, bonding, material)

Request a Quote · Download the Rx PDF

Hard Soft Night Guard: Product Overview

A hard soft night guard is a dual-laminate occlusal appliance we fabricate one at a time to a written prescription. The intaglio side is a soft thermoformable sheet that cushions tooth contact; the occlusal side is a hard sheet that carries the load and resists wear. Clinicians describe this appliance as a night guard soft inside hard outside; in professional coding, a hard soft occlusal guard. A dual-laminate build is what makes the two work as one appliance.

Indications the guard is designed for (clinical judgment stays with the dentist):

• Nocturnal bruxism where an all-hard splint is not tolerated
• Mixed clenching and grinding with moderate wear
• Interim protection after a large restoration is placed
• Cases where compliance on a full-hard guard has been poor

Not designed for: obstructive sleep apnea appliances, mandibular advancement, protrusive repositioning, TMJ diagnostic appliances, or NTI-style anterior-only devices. Ask us and we can quote those separately.

Night Guard Soft Inside Hard Outside Specifications 

Default recipe, if the Rx does not specify: 1.5 mm polyurethane inner + 1.5 mm copolyester outer, flat-plane occlusion, full arch, standard mid-buccal extension, machine polish.

Materials

Soft Inner Layer

Hard Outer Layer

Material batch, brand, country of origin, and certificate of conformity are traceable per case. Ask on the Rx and documentation ships with the appliance.

Our Hard Soft Night Guard Fabrication Process 

We make these in-house on pressure thermoforming machines. No third-party outsourcing. The process is what controls whether the two layers stay bonded, so it matters:

1. Model prep — die-stone pour, base trim, undercut block-out where the Rx indicates.
2. Sheet selection — soft sheet on the model side, hard sheet on the occlusal side, thicknesses per Rx.
3. Heat and form — uniform heat until the sheets reach forming temperature, then stable pressure over the model.
4. Hold-pressure cool-down — pressure is held while the laminate cools at a controlled rate. This is the step most home / chairside setups skip, and it is the main reason store-bought or rushed appliances delaminate early.
5. Trim, polish, QC — margins finished, retention checked on the model, thickness verified with calipers at multiple points.

Fabrication capacity: our removable department runs 4,000 cases per month off-season and up to 6,500 per month during peak periods. Occlusal appliances share that line, so lead time is stable even in surge weeks.

Quality Control

Every appliance is checked against the Rx before it ships:

• Thickness — caliper spot-checks at multiple points against the prescribed value
• Margins — smooth, rounded, no sharp extensions
• Retention — try-in on the stone model, seats fully under light finger pressure
• Integrity — no cracks, no bubbles, no delamination visible at the layer interface
• Occlusion — bilateral contact per the requested occlusal scheme

Every case is logged with technician ID, machine ID, material batch, and QC results. Records archive per case for traceability.

Rx and Ordering

To open a case for a hard soft night guard, we need three things: an impression or a scan, a bite registration, and an Rx.

What to Send

On bite registration for a hard soft occlusal guard: we ask for PVS/VPS or polyether in centric occlusion. Please do not send a wax bite. Wax softens at room and hand temperature, deforms during international transit, compresses under pressure, and does not capture cuspal detail — a distorted bite gives a low or off-center guard and forces a remake.

Rx Fields (required)

• Patient ID or case reference
• Arch (maxillary / mandibular / both as separate cases)
• Total thickness · soft layer thickness · hard layer thickness
• Soft material · hard material (or “default” for our standard recipe)
• Occlusal scheme (flat plane / canine guidance / anterior ramp)
• Cutouts or relief (ortho brackets, implants, restorations, tori)
• Shade / clarity notes if any
• Requested ship date (or “standard”)

A night guard soft inside hard outside takes the same Rx fields as any full-coverage occlusal splint; the two layer thicknesses are the only additional entries.

Ordering Path

1. Send — case files via portal, courier, or FedEx / UPS pickup
2. Design confirm — we reply within one business day with any missing-data flags; the design-confirm clock is separate from turnaround
3. Fabricate — 5–7 business days from a complete case
4. Ship — carrier of your choice or our default (USPS Priority / UPS Ground)

Turnaround, Shipping, Warranty

Service life (patient side, out of warranty): 1–3 years depending on grinding intensity, cleaning habits, and nightly vs occasional wear. Replace at first sign of through-wear on the occlusal surface, edge thinning, or layer separation.

Delamination — What It Is and How We Prevent It

Layer separation is the failure mode buyers ask about most. It happens when the bond between the soft and hard layers gives way. We control it on our side, and we ask you to help patients control it on theirs.

Our side, on every dual-laminate build:

• Hold-pressure cool-down (step 4 above) — the biggest single factor for a durable dual-laminate bond
• Sheet selection tested for lamination compatibility, not just individual properties
• QC checks the layer interface on every case before it ships

Patient side, please include in your delivery instructions:

• Rinse and brush with cool water and a soft toothbrush, no toothpaste
• Air-dry before storing in the case
• No hot water, no denture-cleaning tablets, no bleach or peroxide solutions
• No mouthwash soak
• Bring the guard to hygiene visits every six months for inspection

If a hard soft night guard delaminates within the 90-day warranty and cleaning has been correct, we remake it at no charge. If delamination shows up later and cleaning history points to hot water or denture tablets, the sheet vendors and we classify that as care-related rather than a fabrication defect.

Compliance and Traceability

Lab side — we operate under an ISO 13485 quality management system. Every case is logged with technician, materials, batch numbers, and QC records; records are archived for traceability.

Material side — sheet suppliers carry CE marking and biocompatibility documentation from the ISO 10993 family. Material safety data sheets, certificates of conformity, batch numbers, and country-of-origin documents are available per case on request.

Establishment side — our facility is registered with the U.S. FDA as a dental device establishment, and we maintain the corresponding EU representative and MDR Annex XIII paperwork for our custom-restoration listings (crowns, bridges, inlays and onlays, veneers, custom implant abutments and superstructures, full and partial dentures, and temporary restorations).

Important note on what these records mean. Registration, listing, and notification are administrative records of market access. They are not equivalent to pre-market clearance or product-level regulatory endorsement, and we don’t use that kind of language on our appliances. Occlusal guards are fabricated one at a time to a written prescription for an individual patient, which places them under the custom-device regulatory pathway rather than the pre-market clearance pathway. If your jurisdiction requires specific paperwork for occlusal appliances, tell us and we’ll compile the documentation for that case.

White-Label

Available for outsourcing labs. Neutral packaging, no ASD branding on the case, invoice slip, or shipping label. Set up once during account onboarding and it applies to every downstream order. Standard on our end — no upcharge.

Pricing and Account Terms

• Case pricing is quoted on the Rx before fabrication starts; nothing gets billed above the quote
• No hidden setup fee, no monthly minimum for referring dentists or small clinics — cover shipping and we can work with you
• For outsourcing labs, a monthly volume threshold applies to open a wholesale account; ask us for the current threshold
• Payment terms and account setup handled during onboarding

Hard Soft Night Guard FAQs 

Order a Case

• Send a case — use your portal login or courier a case package
• Request a quote — reply with the Rx fields above and we’ll price the case within one business day
• Talk through a case first — if the case is unusual (severe wear, combined ortho, restorative in progress), a five-minute call with our technical lead usually saves a remake