As part of a U.S. Army funded initiative, Tool worked through years of research to develop insights to use for developing a mouthguard for the military. We lab tested dozens of materials, created forming dentitions for testing existing product, orchestrated speech analysis sessions, and even compression molded blank guards to trim and comfort test.
Our final phase of work included a commercialization effort, so we connected with one of the largest manufacturers to build the best solution on the market. While working with Shockdoctor, I worked out a variety of mouthguard concepts designed to improve impact protection, communication, forming and fit. We paired our thinking with the brands industry knowledge and resources to manufacture the guard domestically.
The final design is built with three core materials that each play a part in the functionality. The outer layer protects against impact and raises the jawline to improve breathing, the mid-layer shapes to the teeth and creates the snap-like retention, while the inner gel layer provides the comfort on the gums after forming. The biggest challenge was engineering the lamination geometry so the materials remain bonded before and after the consumer shapes the guard in hot water. We solved this by interlocking the layers in unique ways along the jaw pads and on the side walls.
Work completed in 2018
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