Pressure Fabrication Instructions


Important: For best results, do not open the foil pouch until immediately before use. The Zendura dental appliance sheet must be thermoformed within 15 minutes of opening the protective pouch. This open time is reduced for very humid environments. Store the Zendura sheets packaged and in a cool and dry place.

Cautions:Patients with a history of allergic reactions to plastics should refrain from using this product. Improper thermoforming of the Zendura sheets might lead to the cracking, sharp edges, loose fit or aspiration of the Zendura appliance.

Model Preparation

  1. The model should be well cured and dry.
  2. The model should be trimmed to be around 3/4—1" high.
  3. Fill in any holes or undercuts with blockout material and let dry.
  4. Coat the model with foil liquid separator or mold release agent to prevent the appliance from sticking to the model, and let dry.

Thermoforming Process

  1. Turn on thermoformer and adjust correct code or heating time for Zendura sheet.
  2. Thermoforming using a pressure of 3 bar (45 psi) or above. A higher pressure is preferable.
  3. Preheating the thermoformer before placing the model on platform.
  4. Open foil pouch and place Zendura sheet on the thermoforming frame. For flip-over type of thermoformer, place the matte surface up; for vertical type of thermoformer, place the matte surface down.
  5. Swing heating element over Zendurasheet to begin heating until the sheet is ready to be formed.
  6. Form Zendura sheet over the model with pressurized air.
  7. Allow the part to cool before handling.

Suggested Settings

Note: The heating element of each thermoformer can vary from machine to machine. The heating cycle times listed in the table are recommended based on our lab experience, but may need to be adjusted by adding or reducing up to 5-10 seconds according to the condition and performance of your specific machine. 

If the material becomes flimsy and folds, it is overheated. Try reducing the heating time by 5 seconds or more if overheating issues persist.

If the material doesn’t adapt to the model well or comes off the model too easily, it is underheated. Try increasing the heating time by 5-10 sec to allow enough heating. 

For example, try code 152 with Biostar if the sheet appears to be overheated, and try code 172 if the sheet appears to be underheated. 

Feel Free to contact us for additional support.

Also See Trimming Techniques; Thermoforming Tips.