Limited first run

Your retainer and your aligner. One case.

Name: Double Jaw Travel Case
Brand: Double Jaw

A screw-top travel case for your wire retainer, also called a Hawley, and your clear aligner. Each sits flat on its own level. Designed, built and field-tested in Jupiter, Florida.

$60Free US shipping

Reserve one See the testing

No cost to reserve. No card. Not an order.

The Double Jaw travel case in black, with its vented screw lid and a clip through the loop — 3D render of the production case in black.

“I've had double jaw surgery and braces, and I'll wear a retainer for life. I used to carry two cases: a small one for my clear aligner and a bigger one for my Hawley. The cases made for both were oversized denture cases. They rattled, sat at an angle and never felt secure. I tested 15 cases, then designed my own. Twenty prototypes later, this is it.”

Blake Hickey · Designer · Jupiter, Florida

Failure analysis

Why it exists.

The original kit: a tough yellow case for the Hawley and a small white case for the aligner, with a tracker stuck to it. Each replacement failed in a new way.

The original yellow hinged retainer case, closed — **01 · The original.** Cheap, hinged and about as tough as a case gets. It carried the Hawley only.

The original yellow case, cracked at the hinge and separated into two halves — **02 · Hinge failure.** A loaded cooler slid onto my bag on a camping trip. When I opened the bag, the case was cracked and open.

15cases testedbefore prototype one

03 · Everything else. Clips that came off. Trays that wobbled. Cases large enough for both were oversized, sat at an angle and rattled, even packed with paper towel.

A bent retainer means a rushed trip to the orthodontist. On a weekend, or in another country, it's worse. Most people own one retainer. This case protects it, and it's only slightly larger than the case you carry now.

Exploded view: lid, tracker, tracker cap, aligner basket and base

Architecture

Engineered around two appliances.

Retention: The lid screws down onto the aligner basket and holds it in its seat.
Closure: Nearly three full turns of thread. No hinge to bend and no latch to release under load.
Separation: The Hawley rests flat on the lower level. The aligner sits above it in its own basket.
Tracking: A pocket in the lid holds an Apple AirTag. Tested with first- and second-generation AirTag.
Attachment: Clip included. Thick, one piece, with a spring gate.
Ventilation: Air moves through both levels and out the vented lid.
Packing: A folded paper towel fills the remaining clearance, stops movement and absorbs moisture.
Drainage: Open cylindrical base that rinses clean and holds water when needed. Radial channels underneath shed water on a wet counter.

Validation

Tested in the field.

Three days below deck in 100°F heat. Three days in a snowboard bag. A mountain bike trip. One impact test with a baseball bat.

The early black prototype after the bat test, with a crack in the lid rim and the base intact — Early prototype after impact. Lid cracked. Base held. The current design is stronger.

A prototype clipped to a dry bag, drying out after a dive — Clipped to a dive bag to dry.

A prototype in a mountain bike bag, seen through the wheel spokes — Packed under mountain bike gear.

A prototype with its clip in a waterproof dopp kit — In a waterproof dopp kit.

Unedited photos of prototypes in use. Prototypes are white. Production units are black.

The case cut in half: solid walls, threads, the basket hanging from the rim and a tracker in the lid

Section view

Cross-section.

The basket is suspended from a continuous ledge around the rim. It cannot drop onto the Hawley. The tracker sits in the lid, out of sight.

Dimensions: 85 mm diameter × 59 mm
Finish: Black. Mark debossed in the lid
Contents: Case, aligner basket, tracker cap, clip

First run

Reserve yours. It's free.

Travel case, blackIncluded
Aligner basket and tracker capIncluded
Bag clipIncluded
AirTag pocketBuilt in
Shipping in the USFree
First access, 72-hour windowReservers

$60or 2 for $100

Reserve at no cost. No card. Not an order.
When the first run opens, you get the checkout link first. First come, first served.
Each unit is built, inspected, bagged and shipped free in the US.

The first run is 50 cases, each built and inspected by hand. If it sells out, you move to the front of the next one. The ship window and return terms are shown before payment. Unopened units can be returned within 14 days.

Fit

Check fit.

Most adult Hawleys and aligners fit. Measure in under a minute. No calipers required.

Wire retainer (Hawley)Up to 58 × 42 mm, 25 mm tall

Clear alignerUp to 68 × 48 mm, 14 mm tall

A Hawley pushed into the corner of two rulers laid in an L, with A read on the bottom ruler and B on the upright ruler

Width and length

Two rulers in an L

Set two rulers in an L with both zeros at the corner. Seat the appliance in the corner. Read A at the widest point and B at the front edge.

One ruler: measure across the widest point, then front to back.

Height

A card on top

Rest the appliance on a flat surface. Lay a card across the top. Read C where the card meets a vertical ruler.

Near a limit? Send your measurements

Questions

Questions.

Does reserving cost anything?

No. No card, and it is not an order. When Batch 01 opens, reservers receive the checkout link first, with a 72-hour window.

When does it ship?

Sales are not open yet. A specific ship window is shown before payment.

Will it rattle?

The lid clamps the basket, so the case does not rattle. Appliances vary in size, so each level has deliberate clearance. A folded paper towel takes up the rest.

Can I soak my retainer in it?

Yes. The base is designed to hold water when you need it. For routine soaking, a glass works better than plastic, especially with cleaning tablets. Follow your orthodontist's instructions and let the case dry before packing.

Can a toothbrush go in it?

Not recommended. A loose toothbrush can strike the Hawley, which is acrylic. The case is designed for the two appliances only.

How is it made?

Each unit is 3D printed to order and finished by hand. Fine layer lines are visible. Hand wash only. This is a travel and storage case; it is not sterile and does not clean.

Are the photos real?

The field photos are unedited photos of prototypes in use. The black product images are 3D renders of the current design. Photos of production units will be added before sales open.

Something else?

For orthodontists: your logo on the lid

Cases for your patients, with your practice's mark pressed into the lid.

Designed and made by Blake Hickey in Jupiter, Florida. Double Jaw is a brand of Hickey Media LLC. Not a toy; keep the case, clip and tracker away from young children and pets. Apple and AirTag are trademarks of Apple Inc. This case isn't made, approved or endorsed by Apple or any retainer or aligner maker.