Vacuum Fabrication Instructions


(Zendura REF 9164)

SKU# 9164 is the Zendura sheet dimension most commonly used with vacuum thermoformers.

Intended Use: 
Zendura Thermoformable Sheet Materials are intended for prescription use in the fabrication of orthodontic and dental appliances.

Zendura® Thermoformable Sheet Materials allow the fabrication of orthodontic and dental appliances such as aligners, bite plates, mouthguards, nightguards, snoring appliances, splints, retainers, repositioners, and temporary bridges.

This material is contraindicated for patients with a history of allergic reaction to plastics.

Excessive heating time during thermoforming will cause plastic to sag with possible risk of injury to operator.

Zendura is provided pre-dried in high barrier packaging and should be thermoformed within 15 minutes of opening its protective pouch.

Model Preparation

1. The model should be well cured and dry.

2. The model should be trimmed to be around 20-25mm (3/4"—1") high.

    3. Assemble any specialized attachment geometry to the model.

    4. Fill in any holes or undercuts with blockout material and let dry.

      5. Suggested: Coat the model with mold release agent to prevent the appliance from sticking to the model and let dry.

          Thermoforming Process:

          1. Turn on and preheat the vacuum thermoformer before using.

          2. Heating time will vary with the type of heating element and period of time the heating element is left on.

          3. Place the Zendura plastic sheet into the thermoformer's sheet holding fixture and the dental model onto its base plate.

          4. Swing the heating element over the sheet.

          5. Observe the plastic as it heats. Zendura sheet should be heated until it sags approximately 1/2 inch.

          6. Move the heating element away from the sheet.

          7. Turn on the thermoformer's vacuum and lower the sheet over the model with a firm force, making sure the sheet's holding fixture is fully seated to allow for proper vacuum.

          8. To achieve better vacuum results, a vacuum "gasket" (e.g., Essix #EVM99) can be used to create concentrated sucking power. 

          9. Trim and finish the appliance (see section  below).

            Note: All heaters will heat the Zendura sheet at different temperatures and rates depending on the type of heating element, voltage, hot/cold environment, distance of plastic sheet to the heater, and condition of the heater. The recommended 1/2 inch in sag of the Zendura sheet will allow it to conform properly over the model.   

            Trimming & Polishing Instructions

            1. Cut Zendura appliance off the model using a trimming wheel or a twist drill (1mm diameter for Zendura material). Operate the trimming wheel or twist drill at around 35,000 rpm and cut as close to the finished outline of the appliance as possible. (We suggest leaving at least 3mm of the gingiva.)


              2. Trim off extra parts with crown & bridge scissors or trimming burs.


              3. Polish the edges of Zendura appliance with an edge polisher at a speed of around 10,000 rpm.

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

                Note: Since Zendura is engineered to have exceptionally high strength, learning to fabricate appliances with this material may require some experimentation. We encourage you to visit for tips on trimming and finishing this material.

                MiniSTAR, MiniSTAR S and Biostar are trademarks of Scheu Dental Technology. Drufomat Scan is trademark of Dreve Dentamid. Erkodent is trademark of ERKODENT Erich Kopp GmbH.

                Click here to download print-ready PDF of IFU covering SKU# 9164, the Zendura sheet dimension most commonly used with vacuum thermoformers. 

                Contact us for additional support.

                Also see Trimming Techniques; Pressure Forming Instructions.