Abstract
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.