Additive Manufacturing of Sports Mouthguards: Mechanical Performance and Impact Validation

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.