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Reducing Appliance Delivery Time by 50% with End-to-End Manufacturing Lab Integration

Connecting practices directly to manufacturing labs with digital ordering, real-time status tracking, and fit calculation engines — cutting delivery time from 3-4 weeks to 10-14 days and reducing remake rates from 20% to 3%.

Build Your Lab Integration Platform

About the Project

A manufacturing lab integration platform that digitizes the full appliance ordering workflow — STL attachment, fit calculations, live production tracking, and delivery scheduling. It removes manual order steps, cuts specification errors, and gives full visibility from order to delivery.

Industry

Healthcare & Dental Sleep Medicine

Oral appliance therapy practices ordering custom devices from manufacturing labs.

  • Dental Sleep Medicine
  • Oral Appliance Therapy
  • Lab Manufacturing
Business Type

Multi-provider practices ordering oral appliances at scale

A practice ordering 30+ appliances per month with zero manufacturing visibility.

  • Multi-Provider
  • 30+ Appliances/Month
  • Multiple Lab Partners
Core Offering

Digital lab ordering with real-time manufacturing status tracking

STL attachment, fit calculations, and digital prescriptions replace email and fax.

  • STL File Attachment
  • Fit Calculation Engine
  • Digital Prescriptions
  • Live Status Pipeline
Manufacturing Workflow

Ordered, produced, QC'd, shipped, delivered

Every appliance tracked through five stages on the patient case dashboard.

  • Order Submission
  • Production Tracking
  • QC Checkpoints
  • Delivery Notification
Integrations

Connected to the Clinical Platform

Delivery notifications auto-schedule the fitting appointment in the patient case.

  • 3D Scan Records
  • Patient Case Dashboard
  • Appointment Scheduling
Build your idea

Talk to our experts

Scope your own lab integration platform with our healthcare engineering team.

  • Free Consultation

The Problem: Manual Orders, Blind Status

Manual ordering caused blind status and costly remakes.

20% Remakes
After diagnosis and treatment planning, ordering oral appliances was a manual nightmare — emailing STL files, faxing prescriptions, calling labs for status updates, and guessing when the appliance would arrive. Miscommunication led to 20% remake rates and 3-4 week average delivery times.
$36K/yr
A multi-provider practice ordering 30+ appliances per month had zero visibility into manufacturing status. Doctors would ask "Where's the appliance?" and the answer was always "Let me call the lab." Remakes alone cost $36K per year.
End-to-End
The goal was to build an end-to-end digital ordering system with fit calculations, automated prescriptions, real-time tracking, and lab performance analytics — all within the existing clinical platform.

From faxing prescriptions and calling labs
to real-time manufacturing dashboards
and 50% faster appliance delivery

Streamline Your Lab Workflow

Our Solution

  • Digital Order & Prescription System

    Digital Order & Prescription System

    Digital Order & Prescription System

    • STL file attachment directly from 3D scan records
    • Fit calculation engine for precise appliance specifications
    • Digital prescription auto-generated from patient case data
  • Jaw Positioning & Specification Engine

    Jaw Positioning & Specification Engine

    Jaw Positioning & Specification Engine

    • Jaw positioning analysis for accurate positioning parameters
    • Specification validation to prevent errors before submission
    • Order submission reduced from 2 days to 5 minutes
  • Real-Time Manufacturing Tracking

    Real-Time Manufacturing Tracking

    Real-Time Manufacturing Tracking

    • Live pipeline: Ordered → Production → QC → Shipped → Delivered
    • Appliance status visible on the patient case dashboard
    • Delivery notification triggers fitting appointment auto-scheduling
  • Lab Communication & Analytics

    Lab Communication & Analytics

    Lab Communication & Analytics

    • Lab-to-practice messaging within the platform
    • Lab performance analytics: turnaround time, remake rate, quality scores
    • Full audit trail of every order, change, and communication
  • Remake & Warranty Handling

    Remake & Warranty Handling

    Remake & Warranty Handling

    • Remake requests raised from the original order with scan and specs attached
    • Root-cause tagging separates lab defects from fit and prescription issues
    • Warranty status and remake cost tracked per lab

Challenges: Manual Ordering and Zero Visibility

Hover a row to see what changed.

Why This Platform Transforms Appliance Manufacturing Workflows

We built a fully digital lab integration that connects practices to manufacturing labs with automated ordering, fit calculations, real-time tracking, and performance analytics — all within the clinical workflow.

The Impact: Digital Lab Integration Transforms Manufacturing Workflows

Every number below was measured in production after launch — not projected in a pitch deck.

50%

Faster Delivery — 3-4 Weeks Down to 10-14 Days

3%

Remake Rate — Down from 20%

$31K

Saved Per Year — On Remake Costs Alone

5 min

Order Submission — Down from 2 Days

Global presence

Three offices. One team.

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