3D printed nylon has transformed the way we design and deliver oral appliances for sleep-disordered breathing and bruxism. Through advanced digital design, laser-sintered manufacturing, and premium vapour-polished finishing, every appliance in the 3D Sleep range offers superior strength, a precise fit, and exceptional patient comfort.
Traditional acrylic and dual-laminate materials can be bulky and prone to fracture. In contrast, 3D printed nylon enables thinner, lighter, and significantly more durable designs - supporting better compliance and long-term success.
From the versatile 3DS Advance and space-saving 3DS Eclipse, to the 3DS Connect for jaw-dropping and the protective 3DS Protect, each appliance is engineered for reliability, comfort, and patient satisfaction.
Innovative dorsal wing design for enhanced comfort
The 3DS Advance is a 3D-printed nylon appliance with a dorsal wing design and is our most popular custom-made device. Manufactured using laser-sintered nylon and finished with a premium vapour-polished surface, it delivers exceptional strength, a precise fit, and smooth patient comfort.
Its unique structure allows the upper and lower components to move independently, reducing stress on teeth and improving overall tolerability. The lateral fins maintain mandibular advancement even during mouth opening, allowing natural movements such as speaking and drinking.
Minimalist design for patients with limited oral space
The 3DS Eclipse is crafted from medical-grade nylon, finished with a premium vapour-polished surface, and incorporates German-designed side connectors. This appliance is particularly suitable for patients with narrow arches, limited intra-oral space, or a pronounced gag reflex.
Australian-designed appliance for mouth breathers
The 3DS Connect is an Australian innovation backed by scientific studies demonstrating its effectiveness and comfort. It is specifically indicated for patients who tend to sleep with their mouths open, as it prevents jaw dropping - a factor that can diminish the efficacy of oral appliances.
While various designs of custom-made mandibular advancement splints (MAS) have been shown to be similarly effective in treating snoring and OSA, two critical factors influence successful outcomes:
The material's type, thickness, and overall design significantly impact patient comfort and, consequently, compliance. Appliances made from 3D-printed nylon are notably thin and lightweight, enhancing patient acceptance.
3D-printed nylon appliances offer exceptional strength and durability, further enhanced by vapour-polished finishing. This significantly reduces the risk of fracture - a common issue with acrylic appliances - and supports long-term effectiveness and patient satisfaction.
The 3DS Protect represents the forefront of occlusal splint technology. Utilising laser-sintered 3D printed nylon, this appliance offers unparalleled strength and comfort:
"Nylon appliances are lightweight, sleek, minimally imposing on tongue space and have no reported allergic reactions…..real life experience with them has demonstrated that the nylon material is much more durable than the acrylic we have been accustomed to using in dentistry.
These appliances are unlike anything we have used in dentistry to date.”
"3D printing using nylon represents the biggest breakthrough I have seen in the field of dental sleep medicine. It’s a new world of minimal, unobtrusive appliances.
While the appliances are extremely thin, we have not had a single fracture in two years of use in our clinic. I, and all my colleagues who are using 3D printed nylon, believe acrylic resin will soon be obsolete for use in oral sleep appliances.”
"I am using an oral appliance myself and recommending them to my patients who have problems with snoring and sleep apnoea.
I’m very impressed with the comfort and effectiveness of the new 3D printed nylon appliances.”
"A long term patient had worn through two acrylic sleep appliances in about seven years because of bruxism. I changed him to a 3D Sleep nylon dorsal appliance and I rang him after five weeks and he is extremely pleased.
He was considering CPAP as his previous appliances worked but were uncomfortable. He now states that he will not be going in that direction as this appliance is really comfortable!”
