Thickness and fit of mouthguards adjusted by notching thermoplastic sheets under different heating conditions

This study examines the thickness and fit of mouthguards by notching thermoplastic copolymer ethylene vinyl acetate (EVA) sheets and then heating them to various degrees. The material used was a 3.8-mm-thick sports mouthguard. Notches with a length of 90 and 80 mm were cut into an EVA sheet 20 mm from the anterior and posterior margins and 15 mm from the right and left margins, respectively, and the sheet was compared with the original. The sheets were formed using a vacuum former when the sheets were heated until they hung 1.5, 2.0, 2.5, and 3.0 cm from the baseline. We measured the thickness and fit of the mouthguard at the central incisor and first molar. Differences in thickness and fit according to the measurement parts, sheet type, and heating conditions were analyzed by three-way anova. The measurement parts and sheet type significantly differed (P < 0.01), and the notched sheet maintained the required thickness. Fit differed among the measurement parts and by heating conditions (P < 0.01), but was not affected by the notching. The mouthguard fit was optimal when the sheets were heated to a hanging distance of 3.0 cm. These results suggest that the thickness and fit of the EVA sheet could be maintained by notching and heating the sheet to a hanging distance of 3.0 cm. These findings could be useful for fabricating appropriate mouthguards.