Sports activities can increase participants’ risk of orofacial trauma. Therefore, it is crucial to have a comprehensive understanding of various types of sports mouthguards. This study aims to present a narrative literature review on ergonomic mouthguards, including their indications for use, classifications, materials, manufacturing methods, and the current status of additive manufacturing in their production. Research of the existing literature was performed in the Google Scholar, MEDLINE/PubMed, Web of Science, and ScienceDirect databases to identify the currently available publications on the topic of sports mouthguards from January 1951 to August 2023. The terms used were “sports mouthguard”, “mouthguards and orofacial traumas”, and “mouthguards and additive manufacturing”. A total of 920 articles were found, and 39 articles were selected and included in this review. While consensus exists regarding the significance of using sports mouthguards with optimal attributes, there is a need for standardization in the methodology for manufacturing custom-made mouthguards. These can be fashioned with conventional ethylene vinyl acetate (EVA) copolymer reinforcements. Such standardization would ensure uniform stress distribution and guarantee ample protection for oral tissues, allowing for universal reproducibility among dental practitioners. Additive manufacturing stands as an innovative method for fabricating mouthguards, displaying promising benefits. However, the materials and methodologies employed in this workflow still require refinement and characterization for a safe clinical integration.

Graded zirconia ceramics balance the high strength of 3Y-TZP with the translucency of 5Y-PSZ through their layered microstructure. However, the mechanical behavior of distinct compositional zones, particularly the transition zone, remains insufficiently characterized under dynamic loading conditions. This study aimed to evaluate the influence of different sintering protocols and thicknesses on the impact strength of graded zirconia. Specimens were sectioned by layer (3Y-TZP, transition zone, 5Y-PSZ) under two thicknesses (1.0 and 1.5 mm) and two sintering protocols (conventional and speed). Impact strength testing, finite element analysis, and fractographic analysis were performed. A total of 180 bars were tested using the Dynstat method, with results analyzed via three-way ANOVA ( = 0.05). The 3Y-TZP layer exhibited the highest impact strength (46.8-66.7 kJ/m²), followed by the transition zone (23.7-41.9 kJ/m²) and 5Y-PSZ (15.5-28.7 kJ/m²). A significant three-way interaction (F2,168 = 5.080, p = 0.007) was observed, with thicker 5Y-PSZ specimens showing ~45% less resistance under speed sintering. Fractographic analysis revealed intergranular fracture without delamination, confirming structural integrity. The 3Y-TZP layer provides superior impact resistance regardless of processing conditions, while conventional sintering is preferable for thicker 5Y-PSZ layers. These findings inform material selection and manufacturing processes for graded zirconia restorations in high-stress applications.