As part of a U.S. Army–funded initiative, TOOL spent several years conducting extensive research to develop insights for a next-generation military mouthguard. Our early efforts included lab testing a wide range of materials, forming dentitions to evaluate fit and retention, orchestrating speech analysis sessions, and compression molding blank guards for comfort testing and trimming trials.
In the final phase of the project, our work shifted toward commercialization. We partnered with Shock Doctor—one of the industry’s leading mouthguard manufacturers—to bring the product to market. I led the concept development of multiple guard designs focused on improving impact protection, communication clarity, formability, and comfort. Working closely with Shock Doctor’s internal team, we aligned our user-centered design approach with their manufacturing expertise to produce the mouthguard domestically.
The final product features a three-material construction, each component purposefully engineered for performance:
The rigid outer layer deflects impact and subtly raises the jawline to improve airflow and breathing.
The mid-layer is a formable structure that molds to the teeth and creates a satisfying snap-fit for secure retention.
The inner gel layer cushions the gums and delivers long-term comfort post-formation.
One of the biggest technical challenges was ensuring proper lamination between layers—both before and after the consumer shapes the guard in hot water. We solved this by designing interlocking geometries along the jaw pads and side walls, which ensured a durable bond throughout the product’s lifecycle.
Work completed in 2018
Available at Shockdoctor online store.