Oral appliances with major connectors and methods for manufacture

An oral appliance, comprising:

• a first body configured to be secured over one or more teeth of a user, the first body comprising a composite structure, the composite structure comprising at least an outer layer secured over an inner layer, the first body further defining at least a first bite pad comprising at least a first spacer secured between the outer layer and the inner layer, the first bite pad in a position to contact at least one of a molar and a premolar of a user, an inner surface of the inner layer defining an exterior shape of the teeth of the user, the first spacer defining a spacer outer surface and a spacer channel surface with at least a portion of at least one of the spacer outer surface and the spacer channel surface having a substantially planar configuration and the first spacer formed from a material having a durometer of at least 60D to resist substantial deformation and retaining a substantially planar configuration between at least two cusps of the teeth of the user when the teeth of the user are clenched;
• a second body configured to be secured over one or more teeth of a user, the second body comprising a composite structure, the composite structure comprising at least an outer layer secured over an inner layer, the second body further defining at least a second bite pad, the composite structure at the second bite pad comprising at least a second spacer secured between the outer layer and the inner layer, the second bite pad in a position to contact at least one of a molar and a premolar of a user, an inner surface of the inner layer defining an exterior shape of the teeth of the user, the second spacer defining a spacer outer surface and a spacer channel surface with at least a portion of at least one of the spacer outer surface and the spacer channel surface having a substantially planar configuration and the first spacer formed from a material having a durometer of at least 60D to resist substantial deformation and retaining a substantially planar configuration between at least two cusps of the teeth of the user when the teeth of the user are clenched;
• a major connector defining a first mounting portion and a second mounting portion, the first mounting portion secured to the first body and the second mounting portion secured to the second body.