Multi-Material 3D Printing of a Customized Sports Mouth Guard: Proof-of-Concept Clinical Case

Abstract

A multilayer mouth guard is known to have the best protective performance. However, its manufacturing in a digital workflow may be challenging with regards to virtual design and materialization. The present case demonstrates a pathway to fabricate a multilayer individualized mouth guard in a fully digital workflow, which starts with intraoral scanning. A free-form CAD software was used for the virtual design. Two various CAM techniques were used, including Polyjet 3D printing of rubber-like soft material and silicone printing using Drop-on-Demand technique. For both methods the outer layer was manufactured from more rigid materials to facilitate its protective function; the inner layer was printed from a softer material to aid a better adaptation to mucosa and teeth. Both 3D printed multilayer mouth guards showed a clinically acceptable fit and were met with patient appraisal. Their protective capacities must be evaluated in further clinical studies.

Sports mouthguard overview: Materials, fabrication techniques, existing standards, and future research needs

“…Additive SM fabrication is presently available but processes are undergoing further development. 56,87,[103][104][105][106] Additive fabrication provides the advantage of precise control of fabrication techniques, the construction of detailed internal features, which all may provide greater SM performance and retention as compared to current manufacturing methods. [104][105][106] Reported fabrication methods include fused deposition modeling, which entails a layer-by-layer technique of heated filaments placed from an extrusion head.…”

“…87,106 Additive SM manufacturing materials include EVA, but thermoplastic coployesters, 104 polylactic acid, polystyrene, polymethyl methacrylate, polyurethane, and proprietary polymers materials have also been investigated. 87,[103][104][105] Furthermore, polyetherketone (PEEK) mouthguards fabricated from a subtractive method have been proposed. 56 Presently, new or modified materials for additive SM fabrication are not described by any current dental standards.…”

“…Additive SM fabrication is presently available but processes are undergoing further development 56,87,103–106 . Additive fabrication provides the advantage of precise control of fabrication techniques, the construction of detailed internal features, which all may provide greater SM performance and retention as compared to current manufacturing methods 104–106 .…”

“…Photopolymer jetting uses a light‐curable polymer that is placed on a building platform from an inkjet‐type printing head and cured layer by layer 87,106 . Additive SM manufacturing materials include EVA, but thermoplastic coployesters, 104 polylactic acid, polystyrene, polymethyl methacrylate, polyurethane, and proprietary polymers materials have also been investigated 87,103–105 . Furthermore, polyetherketone (PEEK) mouthguards fabricated from a subtractive method have been proposed 56 .…”

Influence of New Technology in Dental Care: A Public Health Perspective

“…With 3D printing, dentists can create highly detailed models of a patient’s teeth, which can be used to design and create customized dental restorations. This technology has reduced the time required to create dental restorations, making the process more efficient and cost-effective [ 2 ].…”