Evaluation of Mechanical Properties of 3D-Printed Polymeric Materials for Possible Application in Mouthguards

Impact Absorption Power of Polyolefin Fused Filament Fabrication 3D-Printed Sports Mouthguards: In Vitro Study

BACKGROUND/AIM

This study aims to evaluate and compare the impact absorption capacities of thermoformed ethylene vinyl acetate (EVA) mouthguards and 3D-printed polyolefin mouthguards used in sports dentistry applications. The objective is to determine whether 3D-printed polyolefin mouthguards offer superior impact toughness compared to traditional EVA mouthguards commonly used in sports settings.

MATERIALS AND METHODS

Six material samples were assessed: five pressure-formed EVA mouthguards (PolyShok, Buffalo Dental, Erkoflex, Proform, and Drufosoft) and one 3D-printed synthetic polymer (polyolefin). The materials were evaluated using a modified American Society for Testing and Materials (ASTM) D256 Test Method A for Izod pendulum impact resistance of plastics. Polyolefin samples were 3D-printed using fused filament fabrication (FFF) technology. Notably, the FFF process included samples printed with notches placed either parallel or perpendicular to the build direction. This orientation served as a study factor, allowing for comparison of material behavior under different printing conditions. Impact testing was conducted using an Izod impact tester to assess the materials' performance under controlled impact conditions.

RESULTS

The study achieved a high power (1.0) in power analysis, indicating strong sensitivity to detect significant differences. Among molded materials, PolyShok showed significantly lower impact toughness compared to others (p = 0.06). The mean impact absorption of EVA materials was 5.4 ± 0.3 kJ/m2, significantly lower than polyolefin materials, which demonstrated 12.9 ± 0.7 kJ/m2 and superior performance (p = 0.0). Horizontal-notched polyolefin samples exhibited higher impact strength compared to vertical-notched samples (p = 0.009).

CONCLUSIONS

3D-printed polyolefin mouthguards exhibited significantly higher impact toughness than thermoformed EVA mouthguards. While EVA materials demonstrated structural robustness, their lower impact resistance and observed tearing in other test specimens suggest the need for alternative testing standards to better reflect real-world conditions. 3D-printed mouthguards fabricated with build orientations perpendicular to the direction of impact demonstrate significantly enhanced impact absorption. Further research into manufacturing methods and testing protocols is recommended to optimize mouthguard performance under impact scenarios.

Digital workflow for the fabrication of custom-fit additively manufactured sports mouthguards with balanced occlusion using an optical jaw tracking system: A dental technique

Custom sports mouthguards are used in various sports to protect teeth, temporomandibular joints, and soft tissues from impact forces. The present article demonstrates a digital workflow to fabricate a 3-dimensionally (3D) printed individualized sports mouthguard. An optical jaw tracking system is used to record a repeatable reference position, and mandibular excursive movements to achieve a completely balanced occlusion. The technique simplifies the fabrication of a custom-fit mouthguard over the conventional approach by providing increased thickness accuracy, control of design, and integration of jaw motion.

The production and materials of mouthguards: Conventional vs additive manufacturing - A systematic review

This investigation presents a critical analysis of mouthguard production, focusing on the evaluation of conventional vs additive manufacturing methods, the materials involved, and aspects such as their failure and prevention. It also summarizes the current trends, perspectives, and the main limitations. It is shown that some of the shortcomings can be solved by implementing additive manufacturing technologies, which are systematically reviewed in this research. Due to the specific materials used to produce mouthguards, there are certain additive manufacturing technologies that dominate and a wide variety of raw materials. The costs vary depending on the technology.

Effect of different materials for conventional and 3D-printed models on the mechanical properties of ethylene-vinyl acetate utilized for fabricating custom-fit mouthguards

BACKGROUND/AIM

The interaction between the ethylene-vinyl acetate (EVA) with distinct materials utilized for obtaining dental models can affect the performance of resulting mouthguards. This study attempted to evaluate the effect of different materials for conventional (dental stone) or 3D-printed (resin) models on EVA's physical and mechanical properties and surface characteristics.

MATERIAL AND METHODS

EVA sheets (Bioart) were laminated over four model types: GIV, conventional Type IV dental stone model (Zhermak); ReG, resin-reinforced Type IV dental stone model (Zero Stone); 3DnT, 3D resin printed model (Anycubic) without surface treatment; 3DT, 3D-printed model (Anycubic) with water-soluble gel (KY Jelly Lubricant, Johnson & Johnson) coating during post-curing process. The EVA specimens were cut following the ISO 37-II standard (n = 30). Shore A hardness was measured before and after plasticization on the contact (internal) or opposite (external) surfaces with the model. The breaking force (F, N), elongation (EL, mm), and ultimate tensile strength (UTS, MPa) were measured using a universal testing machine. Macro-photography and scanning electron microscopy were adopted for classifying the EVA surface alteration. Data were analyzed by one-way ANOVA with repeated measures, followed by Tukey's test (α = .05).

RESULTS

Plasticization significantly decreased Shore A values for the tested EVA regardless of the model type (p < .001). Higher F, El, and UTS values were verified for the EVA with 3DT and GIV models compared to ReG and 3DnT (p < .001). 3DnT models resulted in severe surface alteration and a greater reduction of the mechanical properties of the EVA.

CONCLUSION

The interaction of EVA with 3D resin-printed models without surface treatment or resin-reinforced Type IV dental stone models significantly affected the physical and mechanical properties of this material. The utilization of water-soluble gel coating during the post-curing process of 3D resin printed models improved the mechanical properties of the EVA, similarly when this material was plasticized over conventional Type IV dental stone model.

Design of Customized Mouthguards with Superior Protection Using Digital-Based Technologies and Impact Tests

BACKGROUND

In contact sports, an impact on the jaw can generate destructive stress on the tooth-bone system. Mouthguards can be beneficial in reducing the injury risk by changing the dynamics of the trauma. The material properties of mouthguards and their geometrical/structural attributes influence their protective performance. Custom-made mouthguards are the gold standard, and different configurations have been proposed to improve their protection and comfort. However, the effects of different design variables on the performance of customized mouthguards are not well understood.

RESULTS

Herein, we developed a reliable finite element model to analyze contributing factors to the design of custom-made mouthguards. Accordingly, we evaluated the isolated and combined effect of layers' stiffness, thickness, and space inclusion on the protective capability of customized mouthguards. Our simulations revealed that a harder frontal region could distribute load and absorb impact energy through bending if optimally combined with a space inclusion. Moreover, a softer layer could enlarge the time of impact and absorb its energy by compression. We also showed that mouthguards present similar protection with either permanently bonded or mechanically interlocked components. We 3D-printed different mouthguards with commercial resins and performed impact tests to experimentally validate our simulation findings. The impact tests on the fabricated mouthguards used in this work revealed that significantly higher dental protection could be achieved with 3D-printed configurations than conventionally fabricated customized mouthguards. In particular, the strain on the impacted incisor was attenuated around 50% more with a 3D-printed mouthguard incorporating a hard insert and space in the frontal region than a conventional Playsafe® Heavypro mouthguard.

CONCLUSIONS

The protective performance of a mouthguard could be maximized by optimizing its structural and material properties to reduce the risk of sport-related dental injuries. Combining finite element simulations, additive manufacturing, and impact tests provides an efficient workflow for developing functional mouthguards with higher protectiveness and athlete comfort. We envision the future with 3d-printed custom-mouthguards presenting distinct attributes in different regions that are personalized by the user based on the sport and associated harshness of the impact incidences.

Effect of pre-stress on dynamic finite element analysis of the temporomandibular joint

The pre-stress of the temporomandibular joint (TMJ) at the intercuspal position (ICP) was often neglected, which would cause errors in the finite element analysis. The purpose of this study was to investigate the effect of pre-stress on dynamic finite element analysis of the TMJs. One healthy female adult was recruited for medical imaging and motion data acquisition of the reference position (RP) to the ICP and the clicking teeth. The three-dimensional maxillofacial model including the maxilla, mandible, articular cartilages, discs, and discal attachments was reconstructed. Motion from the RP to the ICP was simulated to obtain pre-stress at the ICP. Two groups of the clicking teeth were simulated: (1) the group without pre-stress (GWoP); (2) the group with pre-stress (GwP). Significant differences were found between the two groups at the initial moment of movement, during the open-mouth phase, and during the collision phase between the upper and lower teeth. The maximum difference in the discal contact stress between both groups was even more than double. The relaxation of the TMJ at the beginning of the mouth opening was simulated in the GwP. In addition, an increase in the TMJ stress during teeth tapping was simulated in the GwP. These were not reflected in the GWoP. If pre-stress at the ICP was not considered, part of the true results would be lost. It is necessary to consider pre-stress in the dynamic finite element analysis of the TMJ.

Influence of 3D Printing Conditions on Some Physical-Mechanical and Technological Properties of PCL Wood-Based Polymer Parts Manufactured by FDM

The paper investigates the influence of some 3D printing conditions on some physical-mechanical and technological properties of polycaprolactone (PCL) wood-based biopolymer parts manufactured by FDM. Parts with 100% infill and the geometry according to ISO 527 Type 1B were printed on a semiprofessional desktop FDM printer. A full factorial design with three independent variables at three levels was considered. Some physical-mechanical properties (weight error, fracture temperature, ultimate tensile strength) and technological properties (top and lateral surface roughness, cutting machinability) were experimentally assessed. For the surface texture analysis, a white light interferometer was used. Regression equations for some of the investigated parameters were obtained and analysed. Higher printing speeds than those usually reported in the existing literature dealing with wood-based polymers' 3D printing had been tested. Overall, the highest level chosen for the printing speed positively influenced the surface roughness and the ultimate tensile strength of the 3D-printed parts. The cutting machinability of the printed parts was investigated by means of cutting force criteria. The results showed that the PCL wood-based polymer analysed in this study had lower machinability than natural wood.

Effect of 3D Printing Process Parameters and Heat Treatment Conditions on the Mechanical Properties and Microstructure of PEEK Parts

Fused deposition modeling (FDM) processed Poly-ether-ether-ketone (PEEK) materials are widely used in aerospace, automobile, biomedical, and electronics industries and other industries due to their excellent mechanical properties, thermal properties, chemical resistance, wear resistance, and biocompatibility, etc. However, the manufacture of PEEK materials and parts utilizing the FDM process faces the challenge of fine-tuning a list of process parameters and heat treatment conditions to reach the best-suiting mechanical properties and microstructures. It is non-trivial to make the selection only according to theoretical analysis while counting on a vast number of experiments is the general situation. Therefore, in this paper, the extrusion rate, filling angle, and printing orientation are investigated to adjust the mechanical properties of 3D-printed PEEK parts; then, a variety of heat treatment conditions were applied to tune the crystallinity and strength. The results show that the best mechanical performance is achieved at 1.0 times the extrusion rate, varied angle cross-fillings with ±10° intervals, and vertical printing. Horizontal printing performs better with reduced warpage. Additionally, both crystallinity and mechanical properties are significantly improved after heat treatment, and the best state is achieved after holding at 300 °C for 2 h. The resulting tensile strength is close to 80% of the strength of injection-molded PEEK parts.