Additive Manufacturing of Sports Mouthguards: Mechanical Performance and Impact Validation

Abstract

Background/Aim: This study tests materials by additive manufacturing methods that will demonstrate impact resistance and structural stability comparable to conventional EVA. Material and Methods: Researchers tested ethylene-vinyl acetate copolymers, thermoplastic polyurethane via fused deposition modeling, and flexible photopolymer resins from liquid crystal display-based three-dimensional printing. Analyses included tensile strength, hardness, and impact resistance. Results: Thermoplastic Polyurethane via fused deposition modeling showed the best combination of elasticity, energy dissipation, and durability. Ethylene-vinyl acetate exhibited lower resilience, and the resins failed prematurely. Increased thickness and structural reinforcement improved protection. Conclusions: The material manufacturing method and design significantly influence a mouthguard's effectiveness. Thermoplastic Polyurethane made with additive manufacturing, especially with reinforced designs, offers superior resilience for high-impact sports, providing a path for customizable, effective, and accessible preventive dentistry.