A dental appliance and method includes injection molding a thermoplastic material to form discs for use in thermoforming. Also, a dental appliance and method of manufacture therefor, includes but is not limited to injection overmolding a thermoplastic polyster-containing material with an thermoplastic elastomer material to form a chemically bonded material, and thermoforming the injection molded chemically bonded material to form the dental appliance.
