How digital workflows are transforming sports mouthguard production

September 1, 2026 - 15:35
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How digital workflows are transforming sports mouthguard production

Digital dentistry is changing the way clinicians capture, design and manufacture dental appliances. Sports mouthguard production is one area where this shift is creating new opportunities for more streamlined and repeatable workflows.

For athletes, particularly those competing at elite and professional level, mouthguards may need to be replaced regularly or produced to consistent specifications. A digital workflow can simplify this process by creating a digital record of the patient’s dentition that can be used throughout the design and production journey.

From scan to finished appliance

Traditionally, producing a custom mouthguard has involved physical impressions and several manual or laboratory-based stages.

With intraoral scanning, clinicians can capture the patient’s dentition digitally, creating a file that can be used for appliance design. This can help reduce reliance on physical impressions and make it easier to communicate information between the dental team and the production process.

3Shape’s digital workflow combines the TRIOS intraoral scanner with Splint Studio software, enabling clinicians to move from digital capture to the design of a sports mouthguard within a connected workflow.

For practices treating athletes, the ability to maintain a digital record can also be valuable when replacement appliances are required or when multiple mouthguards need to be produced with consistent specifications.

A practical clinical workflow

Dr Theodoros Tasopoulos, a prosthodontist based in Athens, demonstrates this approach in a new 3Shape case study.

His experience highlights how digital workflows can help reduce manual steps, improve predictability and facilitate communication between the dental team and athlete.

The case study provides a practical example of how digital scanning and appliance design can work together, rather than considering scanning as a standalone technology.

The wider opportunity for digital dentistry

Sports mouthguards are just one example of how digital workflows are expanding beyond traditional restorative applications.

As practices invest in intraoral scanning, the ability to use digital records across multiple applications can increase the potential value of that technology. Connected workflows spanning capture, design and manufacturing are becoming an increasingly important part of digital dentistry.

For clinicians providing sports dentistry, a digital mouthguard workflow offers an opportunity to explore how technology can simplify appliance production while creating a reusable digital record for future treatment.

Explore the full workflow

Dr Tasopoulos’ case study takes you through the process of creating and producing a sports mouthguard using 3Shape TRIOS 5 and Splint Studio.

Discover the step-by-step digital workflow and see how digital technology can be applied to sports mouthguard production.

To save up to 25% on a purchase of TRIOS 5. Book a chat here, call us on 01183 151 300 or email ukenquiries@3shape.com.

This article is sponsored by 3Shape.

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