Short answer

Prioritize Thermoplastic Polyurethane (TPU) for additive manufacturing of sports mouthguards, and explore structural reinforcements and increased material thickness to maximize impact protection.

Field
Commercial Production
Source
Dental Traumatology (2025)
Method
Experimental testing and comparative analysis
Evidence
Strong effect

Thermoplastic Polyurethane (TPU) produced via fused deposition modeling demonstrates superior elasticity, energy dissipation, and durability for sports mouthguards compared to traditional EVA and other 3D printing resins. This commercial production research insight is drawn from a 2025 study published in Dental Traumatology. Using Experimental testing and comparative analysis, researchers explored how this design variable affects real-world outcomes. The key design takeaway: Prioritize Thermoplastic Polyurethane (TPU) for additive manufacturing of sports mouthguards, and explore structural reinforcements and increased material thickness to maximize impact protection.

Study
Commercial ProductionNew This WeekStrong effect

Additive Manufacturing of Sports Mouthguards: Thermoplastic Polyurethane Offers Superior Impact Resistance

Thermoplastic Polyurethane (TPU) produced via fused deposition modeling demonstrates superior elasticity, energy dissipation, and durability for sports mouthguards compared to traditional EVA and other 3D printing resins.

Dental Traumatology · 2025

01

Key Findings

  • 01Thermoplastic Polyurethane (TPU) via FDM exhibited the best combination of elasticity, energy dissipation, and durability.
  • 02Traditional Ethylene-Vinyl Acetate (EVA) showed lower resilience.
  • 03Flexible photopolymer resins failed prematurely.
  • 04Increased thickness and structural reinforcement improved protective performance.
02

Application

Design takeaway

Prioritize Thermoplastic Polyurethane (TPU) for additive manufacturing of sports mouthguards, and explore structural reinforcements and increased material thickness to maximize impact protection.

How to apply

When designing protective gear for high-impact sports, consider using TPU with additive manufacturing. Experiment with lattice structures or varying wall thicknesses to optimize shock absorption.

Project actions

  • 01When choosing materials for a protective design, research their mechanical properties like elasticity and impact resistance.
  • 02Consider how different manufacturing methods (e.g., 3D printing vs. molding) might affect the final product's performance.
03

Method & Evidence

AimTo evaluate the mechanical performance and impact resistance of additively manufactured mouthguard materials against conventional options.
MethodExperimental testing and comparative analysis
ProcedureResearchers tested ethylene-vinyl acetate (EVA) copolymers, thermoplastic polyurethane (TPU) via fused deposition modeling (FDM), and flexible photopolymer resins from liquid crystal display (LCD)-based 3D printing. Mechanical properties including tensile strength, hardness, and impact resistance were analyzed. Design modifications such as increased thickness and structural reinforcement were also evaluated.
ContextSports protective equipment design, additive manufacturing, material science

Variables

IV["Material type (EVA, TPU, photopolymer resins)","Manufacturing method (FDM, LCD-based 3D printing)","Design modifications (thickness, reinforcement)"]
DV["Tensile strength","Hardness","Impact resistance","Elasticity","Energy dissipation","Durability"]
CV["Sample dimensions (prior to design modifications)","Testing conditions (temperature, humidity)"]
04

Strengths & Limitations

Strengths

  • +Direct comparison of multiple relevant materials and manufacturing techniques.
  • +Inclusion of design modifications to assess their impact on performance.

Limitations

The cost and accessibility of specific 3D printing materials and machines might be a practical limitation for some design projects.

Reliability & validity

Reliability would be enhanced by repeating mechanical tests multiple times on identical samples. Validity is supported by comparing against established materials (EVA) and using standard mechanical testing procedures.

Think critically

How might the long-term biocompatibility and degradation of 3D printed materials like TPU compare to traditional mouthguard materials?

05

Design Principles

"Material properties and manufacturing processes directly influence the functional performance and protective efficacy of sports equipment."

This research highlights how advanced manufacturing techniques and material selection can significantly enhance the protective capabilities of sports equipment. For designers, it points to opportunities for creating more effective, customizable, and potentially more accessible protective gear.

06

What This Means for Your Design

3D printing with a material called TPU makes better mouthguards for sports because it's more flexible and absorbs hits better than older materials.

How to use in your project

  • 1.Reference this study when discussing material selection and manufacturing processes for protective equipment in your design project.
  • 2.Use the findings to justify your choice of materials and manufacturing methods, especially if aiming for improved performance.
07

Add to My Project

08

Quick Cite

Paragraph starter

Research by Gonçalves et al. (2025) indicates that Thermoplastic Polyurethane (TPU) produced via fused deposition modeling offers superior impact resistance and energy dissipation for sports mouthguards compared to traditional EVA and other 3D printing resins. This suggests that designers can leverage additive manufacturing with advanced materials like TPU to create more effective protective equipment, with further improvements possible through structural design modifications such as increased thickness and reinforcement.

09

Source

Dental Traumatology

Additive Manufacturing of Sports Mouthguards: Mechanical Performance and Impact Validation

journal · 2025

View source

Questions About This Research

What does the research say about additive manufacturing of sports mouthguards: thermoplastic polyurethane offers superior impact resistance?
Prioritize Thermoplastic Polyurethane (TPU) for additive manufacturing of sports mouthguards, and explore structural reinforcements and increased material thickness to maximize impact protection. Evidence: Dental Traumatology (2025).
Why does "Additive Manufacturing of Sports Mouthguards: Thermoplastic Polyurethane Offers Superior Impact Resistance" matter for design?
This research highlights how advanced manufacturing techniques and material selection can significantly enhance the protective capabilities of sports equipment. For designers, it points to opportunities for creating more effective, customizable, and potentially more accessible protective gear.
How can designers apply this research?
Prioritize Thermoplastic Polyurethane (TPU) for additive manufacturing of sports mouthguards, and explore structural reinforcements and increased material thickness to maximize impact protection.
What were the main findings?
Thermoplastic Polyurethane (TPU) via FDM exhibited the best combination of elasticity, energy dissipation, and durability.. Traditional Ethylene-Vinyl Acetate (EVA) showed lower resilience.. Flexible photopolymer resins failed prematurely.. Increased thickness and structural reinforcement improved protective performance.
What research method was used?
Experimental testing and comparative analysis.
How strong is the evidence?
Evidence strength is rated Strong effect, based on a 2025 journal from Dental Traumatology.
What should I do differently in my next project?
When designing protective gear for high-impact sports, consider using TPU with additive manufacturing. Experiment with lattice structures or varying wall thicknesses to optimize shock absorption.
What are the limitations?
The study focused on specific materials and additive manufacturing methods; performance may vary with different formulations or printing technologies. Long-term wear and tear were not extensively studied.