Abstract: For improving the functionality and bio-compatibility of dental appliances (2), a novel process is described for making a thermoplastic functional foil (1), from which such dental appliances (2) may be obtained by thermoforming the functional foil (1). A carrier liquid (9) containing an organic and preferably bio-based polymer (6) is enriched with an agent (7) and applied onto a solid thermoplastic core foil (13). After evaporating of a solvent contained in the carrier liquid (9), a uniform and highly homogenous functional coating (5) is obtained on the core foil (13). After thermoforming of the foil (1), the dental appliance (2) thus features an outer protective coating (5) offering enhanced functionality. Moreover, it is possible to reload the agent (7) into the coating (5) of the appliance (2) using a reload-liquid (23).

Abstract: For improving the quality of use of intraoral orthodontic devices (1) such as dental splints (2) to be worn on teeth as well as for increasing their functionality, such devices (1) are fabricated at least in part, but preferably fully from bio-based materials (5). In particular when using a design featuring a cap layer (4) covering an inner stiff core (3) and including a bio-based material (5), which can be additionally chosen such that it can take-up a significant amount of liquid by swelling, both the micro-deformability of the device (1) can be improved—resulting in increased wearing comfort for the patient and less microplastic contamination for the patient through fossil-based plastic abrasions—and novel functions can be realized, for example releasing substances (9) such as drugs or flavor molecules or bio-based antimicrobial or protective agents from the device (1).