Abstract: Methods and systems relate to receiving oral characteristic data of a patient, processing the oral characteristic data in a server to determine dentition data and a forward mandibular position to enable the patient to breathe during sleep by opening an airway of the patient, forming a dental appliance using the dentition data and the forward mandibular position, including a lower dental tray and an upper dental tray, the upper dental tray including a pair of upper dental tray plateaus, the lower dental tray including a pair of lower dental tray plateaus, ultrasonically welding a first pair of button protrusions onto the pair of lower dental tray plateaus, and ultrasonically welding a second pair of button protrusions onto the upper dental tray plateaus to provide a dental when two connectors are attached to connect the upper dental tray to the lower dental tray.