ABSTRACT Objectives This study aimed to optimize additive manufacturing parameters with a specific focus on improving the mechanical performance of materials used for sports mouthguards. The objective was to evaluate impact resistance and fracture behavior as the primary criteria for optimization. Materials and Methods Two additive manufacturing techniques, Fused Deposition Modeling (FDM) and Stereolithography (SLA), were evaluated using four materials: TPU, EVA, DIMA resin, and IBT resin. Specimens were produced under varying layer thicknesses, printing orientations, and raster/angle configurations. Mechanical performance was assessed through Izod impact testing, and fracture morphology was analyzed using scanning electron microscopy (SEM). Results Printing parameters significantly influenced impact resistance across all materials. Under optimized SLA conditions (25 μm, vertical, 90°), DIMA exhibited an impact resistance of 25.6 ± 0.14 kJ/m 2 , while IBT reached 8.64 ± 1.16 kJ/m 2 . For FDM materials, TPU achieved the highest performance at 31.2 ± 1.29 kJ/m 2 , followed by EVA with 21.8 ± 0.35 kJ/m 2 , both printed at 0.08 mm layer height, 60 mm/s, and 90° raster orientation. SEM analysis confirmed that optimized parameters reduced interlayer defects and improved fracture resistance in both technologies. Conclusion Additive manufacturing demonstrated for producing mechanically efficient mouthguard materials when printing parameters are appropriately optimized. TPU and EVA printed via FDM showed impact resistance comparable to commercial EVA, while optimized SLA parameters enhanced resin performance despite inherent brittleness. These findings reinforce AM as a viable alternative for customizable, mechanically optimized mouthguard fabrication.
Gonçalves et al. (Thu,) studied this question.