Methods and systems herein relate to forming an upper dental appliance chassis including at least two upper appliance button protrusions； forming a lower dental appliance chassis including at least two lower appliance button protrusions and at least two vertical displacement bite pads； injection overmolding a first thermoplastic on the upper dental appliance chassis to provide a first reformable thermoplastic layer integrated with the upper dental appliance chassis that exposes the at least two upper appliance button protrusions to form an upper dental tray； and injection overmolding a second thermoplastic on the upper dental appliance chassis to provide a second reformable thermoplastic layer integrated with the lower dental appliance chassis that exposes the at least two lower appliance button protrusions and the at least two vertical displacement bite pads to form a bottom dental tray.
