Effects of aging on the dimensional stability of custom-made mouthguards

Objective: The purpose of this investigation was to assess the effects of aging on the dimensional stability of vacuum-formed, pressure-formed, and pressure-laminated custom-made mouthguards. Method and materials: A master model representing the dental arch was fabricated in acrylic resin. Two ethylene vinyl acetate thermoplastic materials were tested: Essix (regular) and Proform (prelaminated). The model was benchmarked in five places along the curvature of the arch. The model was used to fabricate 10 specimens for each of the following groups: 1 = vacuum-formed (3-mm) Essix; 2 = vacuum-formed (4-mm) Proform; 3 = pressure-formed (3-mm) Essix; 4 = pressure-formed (4-mm) Proform; 5 = pressure-laminated (3-mm + 2-mm) Essix; 6 = pressure-laminated (3-mm + 3-mm) Essix. Die stone was poured into the newly made specimens and measured. Aging of the specimens was simulated by reproducing cleaning cycles (48 hours' soaking in water at 60°F and brushing 100 times with a soft denture brush in soapy water at 140°F for 20 minutes). Die stone was poured into the aged specimens and measured. Initial and post-aging measurements were compared. Results: All specimens showed dimensional changes post-aging, mainly decreases. Pressure-laminated specimens showed the best dimensional stability. Conclusion: Aging induced various dimensional changes in mouthguards, depending on the materials and processing techniques used. Most of the dimensional change for all mouthguards occurred at the central incisor region, the most important area for the protection of the anterior teeth and the premaxilla. Pressure-laminated mouthguard specimens showed the smallest range of changes at the central incisor region, suggesting potentially improved fit, comfort, and protection.