Finishing the Zendura Appliance

by Aaron Stewart September 10, 2012

Zendura has a well-earned reputation for long-term durability and cracking resistance. However, the rigidity and high strength of Zendura make molding and getting the best finish on an appliance more challenging than softer materials. For an office with high aligner/retainer volume, efficiency, reproducibility and charm are the keys to good results and profit. 

Some customers have asked if there are best-practices or useful tips on getting the best finished Zendura parts. We have seen many successful procedures for finishing and trimming parts, though – if what you already do works well, don't feel obligated to change process to match our suggestions.  

We want to make sure everyone has access to best-practices information for efficiency and reproducibility when forming Zendura material. And we are more than happy to share what we think makes for the easiest and most effective Zendura fabrication process.

Mold Preparation Before Thermoforming

1. The model needs to be well cured and dry. 

2. The model should be trimmed (or buried in metal granules) to be around 3/4’’—1’’ high to prevent further stretching (thinning) of the material down the model when thermoforming.


3.Fill in any holes or undercuts with blockout material/resin and let dry.



4. Coat the model with liquid foil separator or model release agent (to prevent the appliance from sticking to the model) and let dry (if using a plastic model, use silicone spray or cooking oil).



Trimming and Finishing

1. Cut Zendura appliance off the foil with a trimming wheel or a twist drill, leaving at least 3mm of the gingiva.  


2. Remove appliance from the model and cut any extra parts with crown & bridge scissors or trimming burs.


3. Polish the edges of Zendura appliance with a polishing brush


4. Rinse Zendura appliance with cool water and mild soap before delivering.


  • Erkogum Blocking Out Materials                                             
  • Perfecta Block-Out Resin (Henry Schein Item #: 4008300)
  • Liquid Foil Separator (GreatLakes Orthodontics Item #: 175-034)
  • Trimming Wheel (Dremel Cut-Off Wheel of your choice, or single-piece cutter)
  • Twist Drill (Komet USA Pg 262, Item#: H219 104 023)
  • Trimming Bur (Dentsply International Item#: 18979W)
  • Scissors (Dentsply International Item#: 18004)
  • Polishing Brushes

Aaron Stewart
Aaron Stewart


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