The present invention provides improved devices, systems and methods for producing dental molds, each having portions representing a patient's oral soft tissue and a desired tooth configuration. These molds are designed for use in the fabrication of appliances used in orthodontic treatment, particularly, elastic repositioning appliances. However, they may also be used in the fabrication of traditional appliances, such as retainers and positioners, used, for example in the final or finishing stages of an otherwise conventional treatment. The dental molds are comprised of a mold or relief of the patient's soft tissue, such as a palate, facial gingival tissue and/or lingual gingival tissue, and a separate or separable mold or relief of the patient's dental arch having teeth in a desired tooth configuration. Since, the tooth configuration will change as a patient progresses through orthodontic treatment, the relief of the dental arch will be fabricated separately from the relief of the oral soft tissue. Typically, the dental arch relief will be fabricated using rapid prototyping methods. The soft tissue relief may also be fabricated using rapid prototyping, however it may also be fabricated using traditional mold making methods, i.e., casting with plaster or other mold making materials. In either case, the resulting dental mold with be comprised of a "split-mold" having fixedly or removably joined arch and soft tissue reliefs.