Full-scanner barrier for an intra-oral device

A method of forming a removable barrier device for covering a handheld intraoral scanner, the method comprising:

• forming a cover adapted to fit over a probe of the scanner by:
• forming a distal portion of the cover by injecting molding a first material, wherein the distal portion includes walls that define an internal cavity, one of the walls including at least one window opening or at least one window formed of the first material;
• forming a proximal portion of the cover by coupling a second material to the first material such that the second material is bonded to the first material, wherein the second material is the same as or is different from the first material, further wherein the proximal portion is bonded to an edge of the walls of the distal portion to form an extension of the walls of the distal portion;
• and
• bonding a flexible sleeve to the proximal portion of the cover such that an interface region between the flexible sleeve and the proximal portion of the cover is resistant to fluid from passing therethrough, wherein the sleeve is adapted to cover a handle of the scanner and is more flexible than the distal portion of the cover.