DRAFT FOR REVIEW — Not Doctor-approved for training. VERIFY items must be cleared before competency use.
Sports Guards
SprintRay SportsGuard — Lab Manufacturing Procedure
Smile Avenue Family Dentistry — In-House Laboratory
SprintRay SportsGuard — Lab Manufacturing Procedure
|
|
| Document ID |
SOP-LAB-100 |
| Version |
0.1 DRAFT |
| Effective (target) |
09/10/2026 |
| Owner |
Lab Technician (process owner) |
| Status |
DRAFT FOR REVIEW |
Start: Case received in Medit Lab with scan QC
End: Sports guard bagged and logged in SEAZONA for outbound delivery
1. Purpose
This procedure standardizes in-house manufacturing of SprintRay SportsGuard athletic mouthguards so every case meets the same quality, safety, and traceability standard before leaving the lab.
2. Scope
In scope: Medit Lab intake → scan QC → design (VERIFY path) → RayWare / Pro 2 → ProWash S (custom 3/5/3) → NanoCure → finish → lab clean → bag & SEAZONA.
Out of scope: Nightguards (SOP-LAB-020); chairside scanning; clinical delivery; non-SprintRay printers. SportsGuard IFU validates Pro 2 only.
3. Roles
| Role |
Responsibility |
| Clinical Assistant / Office |
Sends case via Medit Lab; receives bagged guard |
| Lab Technician |
Scan QC; design approve; manufacture; finish; bag; SEAZONA |
| Trainer / Lead Lab Technician |
Competency observation and sign-off |
| Doctor |
Indication, shade Rx, delivery, remake authorization |
4. Practice Configuration
| # |
Item |
Smile Avenue setting |
| 1 |
Printer |
Pro 2 only (IFU-validated) |
| 2 |
Cure unit |
NanoCure — SportsGuard preprogrammed profile (do not invent minutes) |
| 3 |
Case intake |
Medit Lab |
| 4 |
Design |
VERIFY — outside CAD or SprintRay Cloud Design; follow Appliance Design Guidelines |
| 5 |
Wash |
ProWash S — IPA ≥ 91% — Custom Multi-Cycle: 3 min wash / 5 min rinse / 3 min dry |
| 6 |
Shades |
Clear, red, blue — per Rx |
| 7 |
Layer thickness |
100 µm |
| 8 |
Design approval before print |
Lab Technician |
| 9 |
Case log |
SEAZONA |
5. Safety
- Treat uncured SportsGuard as hazardous. PPE + ventilation.
- Do not bag under-cured appliances. Do not substitute non–Pro 2 printers for this resin.
- Cure waste resin fully. Do not use expired resin.
6. Materials & Equipment
- SprintRay SportsGuard (clear / red / blue)
- IPA ≥ 91%; mineral oil (optional finish)
| Step |
System |
| Intake |
Medit Lab |
| Design |
VERIFY |
| Nest / print |
RayWare Cloud / Dashboard Print Setup → Pro 2 |
| Wash |
ProWash S custom 3/5/3 |
| Cure |
NanoCure — SportsGuard |
| Case log |
SEAZONA |
7. Process Controls
| Gate |
Do not proceed if |
Proceed when |
| Printer |
Not Pro 2 |
Pro 2 only |
| Design |
Not approved |
QC-A pass |
| Wash |
Wrong cycle (e.g. standard 3/3/3 only) |
Custom 3/5/3 complete |
| Pre-cure |
Wet |
Fully dry |
| Cure |
Wrong profile |
SportsGuard profile complete |
| Outbound |
Failed QC-E |
Bagged + SEAZONA |
8. Procedure
A. Intake & scan QC
- Medit Lab: verify ID, arch (typically maxillary), shade, coverage Rx, due date.
- Scan QC; QC-SCAN.
B. Design (VERIFY)
- Design/receive STL per Appliance Design Guidelines.
- Lab Technician approves. QC-A: Coverage/thickness per guidelines; shade noted; STL labeled.
C. Nest (RayWare)
- Auto-orient preferred; SportsGuard material; 100 µm; default supports; Pro 2 queue.
D. Print
- Shake 1 minute; pour; assign; print; log lot. QC-B.
E. Wash & dry
- ProWash S custom multi-cycle 3/5/3, IPA ≥ 91%. Fully dry. QC-C.
F. Post-cure
- NanoCure SportsGuard profile. Remove supports. QC-D.
G. Finish, clean, bag
- Carbide bur for stumps → Scotch-Brite/Fuzzies → optional mineral oil + cotton buff.
- Soap + brush (+ steamer); dry; bag; SEAZONA. QC-E.
End of SOP-LAB-100.
9. Case Log (SEAZONA)
| Field |
Entry |
| Date / case ID |
|
| Shade |
☐ Clear ☐ Red ☐ Blue |
| Scan QC |
☐ Pass ☐ Fail |
| Design approved by (Lab Technician) |
|
| Lot / Pro 2 |
|
| Wash 3/5/3 OK |
☐ Yes |
| NanoCure SportsGuard |
☐ Yes |
| QC pass + bagged |
☐ Yes — time __ |
10. Quality Checkpoints
| ID |
When |
Pass |
Fail action |
| QC-SCAN |
Intake |
Usable |
Return |
| QC-A |
Pre-print |
Approved |
Redesign |
| QC-B |
Post-print |
Complete |
Remake |
| QC-C |
Post-wash |
Clean + dry |
Re-wash/dry |
| QC-D |
Post-cure |
Cured |
Remake / salvage |
| QC-E |
Outbound |
Finish + bag + SEAZONA |
Hold |
11. Remake Criteria
| Finding |
Action |
| Failed scan QC |
Do not manufacture — request new scans |
| Incomplete print / delamination |
Remake print |
| Printed on non–Pro 2 |
Remake on Pro 2 (IFU Pro 2-only) |
| Wrong wash cycle / under-cured / wrong NanoCure profile |
Hold outbound; correct or remake |
| Torn margins after supports |
Remake |
| Light support nubs only |
Salvage — finish and re-check QC-E |
| Unsure |
Stop and escalate to Doctor / lab lead |
12. Competency
| Requirement |
Sign-off |
| Read SOP-LAB-100 |
Tech _ Date ___ |
| Demonstrates custom 3/5/3 wash + SportsGuard NanoCure + process controls |
Trainer _ Date ___ |
| Completes 3 observed cases to bagged outbound with SEAZONA log |
1. __ 2. _ 3. ___ |
| Trainer attests ready |
Trainer _ Date ___ |
| Lab lead authorizes unsupervised production |
_ Date ___ |
13. Troubleshooting & Escalation
| Problem |
Action |
| Bad scans |
QC-SCAN fail → return to office |
| Print failure |
Remake; filter resin; verify Pro 2 material assignment |
| Soft / tacky after cure |
Confirm dry part and SportsGuard NanoCure profile; remake if needed |
| Printed / requested off Pro 2 |
Stop; remake on Pro 2 only |
Escalate to Doctor / lab lead: unclear Rx; allergy; chronic remakes; IFU deviation.
Escalate to office: failed scan QC; missing prescription.
SprintRay Support: 1-800-914-8004 — missing NanoCure SportsGuard profile; repeated Pro 2 failures.
14. References
- SprintRay SportsGuard IFU-034 Revision 2 (effective 06/11/2026)
- Appliance Design Guidelines: https://support.sprintray.com/s/article/Appliance-Design-Guidelines
- Local IFU archive:
SportsGuard.txt
Smile Avenue Family Dentistry — In-House Laboratory · Internal use only
SOP-LAB-100 DRAFT FOR REVIEW · Target effective 09/10/2026 · Supersedes prior draft revisions
Review annually or when SprintRay IFU / equipment changes. Confirm all VERIFY items before training use.
