Abstract: A method includes inserting an irradiated, cross-linked thermoplastic polymer into a pressure chamber of a pressure molding machine, positioning an oral model on a molding platform of the pressure molding machine, applying heat using a heat element to soften the thermoplastic polymer, and applying pressure to form the thermoplastic polymer over the oral model to produce a tray. The method also includes scanning the tray to produce a scanned surface and milling a frame based on the scanned surface. The frame includes a channel that fits the tray. The method further includes inserting the tray into the channel of the frame and coupling the tray to the frame.

Abstract: A method includes forming a first layer of a disk, the first layer comprising a first material and forming a second layer of the disk by depositing a second material on the first layer. The method further includes irradiating at least the second layer of the disk to cross-link the second material. The first material has a higher melting point than the second material, and the dual-layer disk is configured to be thermoformed into an oral appliance.