Clinical–based design of additively manufactured custom sports mouthguards using intraoral scanner integrated splint software

Objective Conventional thermoformed sports mouthguards made from ethylene-vinyl acetate (EVA) often exhibit thickness inconsistencies and limited adaptability, thus reducing protection and compromising athlete compliance. Computer-Aided Design/Computer-Assisted Manufacturing (CAD/CAM) workflows can overcome these limitations. However, their clinical use for sports mouthguards remains limited. Methods Maxillary and mandibular arches were scanned with an intraoral scanner. The occlusal vertical dimension was increased by 2 mm, and centric relation was recorded with a 3D-printed anterior deprogrammer. A sports mouthguard was designed using CAD splint software, specifying a thickness of 3-5 mm labially, 2 mm occlusally, and 1 mm palatally. The design was fabricated using a biocompatible resin via additive manufacturing, post-processed according to the manufacturer's instructions, and clinically evaluated for fit, occlusal contact, and comfort. Results The described workflow repurposes existing CAD splint software to fabricate custom mouthguards for sports. It provides improved thickness control, accuracy, and reproducibility, offering advantages for both athletes and clinicians. Conclusions Future studies should validate long-term clinical performance, material fatigue, and microbiological safety under athletic conditions. Clinical significance The CAD/CAM workflow enables precise, reproducible, and well-adapted sports mouthguards, improving protection, comfort, and compliance compared with conventional thermoforming. It offers clinicians a practical and efficient alternative for custom athletic protection.