Built With Tools Other Mouthguard Labs Don’t Use

Most mouthguards are made the same way they were 20 years ago — hot plastic, a vacuum machine, and manual trimming.

Guard Forge uses fully digital workflows, from scanning to design to resin printing, allowing us to create mouthguards that are more accurate, more protective, and more comfortable than traditional techniques can achieve.

Our lab combines:

  • Intraoral scanning / high-resolution impressions
  • Digital CAD modeling in Exocad
  • Dental-grade resin 3D printing
  • Precision post-curing & finishing

This isn’t just an upgraded process — it’s an entirely different class of mouthguard manufacturing.

Step 1

3D Digital Scan of Your Teeth

Every Guard Forge mouthguard starts with a precise 3D scan of your dentition.
We capture detail down to microns, allowing us to model:

  • Exact tooth anatomy
  • Gum contours
  • Natural bite position
  • Contact points and surface angles

This digital model becomes the blueprint for your customized guard.

If a scan isn’t available, we convert your physical impression into a digital file using lab scanners with the same level of precision.

Step 2

Designed in Exocad for Optimal Fit & Protection

Inside Exocad, we sculpt your mouthguard with complete control over:

  • Thickness distribution (we reinforce impact zones with micrometer precision)
  • Occlusal clearance for airway and comfort
  • Border height for added lip and tooth protection
  • Material flow & flex points for shock absorption

Unlike vacuum-formed guards, which rely on stretching plastic around a mold, CAD design ensures every millimeter of the guard is intentional.

Step 3

Resin 3D Printing With Dental-Grade Materials

Your design is printed using a high-resolution resin printer, the same technology trusted in dental prosthetics and surgical guides.

This gives us:

  • Ultra-precise detail accuracy
  • Consistent thickness across the entire guard
  • Smooth internal surfaces for comfort
  • Superior strength compared to thermoformed materials

Each guard is printed layer-by-layer, resulting in a piece that is strong, perfectly fitted, and hydraulically stable.

Step 4

Cured, Polished, and Lab-Refined

After printing, the mouthguard goes through:

  1. Alcohol wash & ultrasonic cleaning
  2. Post-cure under controlled UV & heat for full material strength
  3. Hand finishing for smooth edges and anatomical comfort
  4. Final fit verification against the digital model

This ensures your guard isn’t just strong — it’s perfected.

The Digital Advantage

Precision Fit

Digital scanning eliminates distortions from alginate or impression warping.

Controlled Thickness

We place strength where impacts happen — instead of relying on stretched plastic sheets.

Repeatable Designs

Lose your guard? We reprint the exact same file — no new impressions required.

This Is the New Standard

Guard Forge isn’t improving mouthguards — we’re redefining them.

By merging advanced dental CAD/CAM workflows with high-precision resin printing, we offer protection and comfort that traditional processes simply cannot match.

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