Mouthguard Molds
(Previous Engineering Work as a Member of Tool., Inc.)

In collaboration with the US Army, TOOL Inc. sought to develop a mouthguard that excels in the realms of impact protection, comfort, and style. To evaluate our designs, I led the engineering effort in modeling and fabricating a series of molds, which were then used to create various mouthguard geometries. 

The first section below shows the development of a full palate mouthguard, made using 3D printed insert geometry and CNC milled outer shells. 

The middle section outlines the molding process using a standard mouthguard geometry. Once molded, the mouthguards are modified and combined with other materials to form unique experimental models. 

The final section highlights an entirely 3D-printed mold, made from a high temperature resin. This mold utilizes an ejector pin system to facilitate part removal.