Not all mouthguards are created equal. The method matters. The materials matter. The quality control matters. Here's how we do it — and why it's different.
Understanding the difference between how mouthguards are made is the key to understanding why they perform so differently.
Shop-bought, £5–£30
A generic, one-size-fits-all blank is dropped into boiling water to soften the material, then the athlete bites into it to create a rough impression. The material cools and hardens in whatever shape it ends up in.
The uncomfortable truth: a boil-and-bite guard gives you a false sense of security. The areas that thin out most are exactly where you get hit hardest.
Cheap online "custom" guards — £30–50
A single sheet of EVA material is heated and draped over a model of your teeth. A vacuum pump sucks the material down around the model. Cheap, fast, and the method most online "custom mouthguard" services use because it's the lowest-cost way to claim a guard is custom-fit.
"Custom-fitted" is doing a lot of work in the marketing copy. Yes, it's shaped to your scan. No, the protection isn't on the same level as pressure lamination. We don't offer this method.
Every guard we make — from £75
Multiple layers of EVA material are bonded together under extreme heat and pressure using a specialised pressure forming machine. Each layer is individually heated and pressed onto the model at 8 bars of pressure — the maximum available from the best equipment on the market. The result is a dense, uniform, multi-layered guard with no air inclusions and consistent thickness throughout. Every single guard we sell is made this way — no exceptions, no cheap vacuum-formed versions.
This is the only method we use. The same manufacturing process behind guards worn by professional fighters and elite athletes — every Basic Pro, Ultra and Max guard built to the same pro-grade standard.
| Boil & Bite | Vacuum Formed | Pressure Laminated | |
|---|---|---|---|
| Fit method | Bite impression | Digital scan | Digital scan |
| Forming pressure | None (manual bite) | ~1 bar (vacuum) | 8 bars |
| Material thickness retention | Uncontrolled (50–75%) | 60–75% | 90%+ |
| Front teeth thickness | 0.5–1.5mm | 2–3mm | 3–4mm (verified) |
| Layers | Single | Single | 2 or 3 |
| Force reduction | Minimal | 30–40% | 50–62% |
| Breathing impact | 14–20% reduced | <4% | <2% |
| Training compliance | 40–50% | ~70% | 80%+ |
| Jaw joint protection | None / harmful | Basic | Bite platform option |
| Quality certificate | No | No | Yes — measured & certified |
| We offer this? | No | No | Yes — every guard |
We don't batch-produce and hope for the best. Every single mouthguard is individually inspected, measured, and certified before it reaches you.
Your guard is built in a specialised dental lab using the highest-specification pressure forming machine available — delivering 8 bars of pressure per layer. This is the maximum available from any commercial machine, ensuring absolute material density and adaptation to your model.
Every finished guard is measured with precision calipers at the anterior (front teeth) zone — the critical area that takes the most impact. We verify the material thickness meets our minimum standards. If it doesn't pass, it gets remade. No exceptions.
A dental professional inspects every guard for proper margins, adaptation quality, surface finish, and overall build quality. Any air inclusions, rough edges, or fit issues are identified and corrected before the guard leaves the lab.
Your mouthguard arrives with its own individual certificate of quality confirming: the guard type, number of layers, measured anterior thickness, forming pressure used, inspection date, and the name of the dental professional who signed it off. This is professional accountability — not a sticker on a box.
Our pressure forming machine operates at 8 bars — the highest specification commercially available. Higher pressure means denser material, fewer air inclusions, tighter adaptation to your dental model, and a guard that maintains its protective thickness exactly where you need it. This is the same class of equipment used by labs that supply professional sports teams.
Your mouthguard isn't made on a factory line. It's crafted in a specialised dental laboratory by technicians who understand the materials, the pressures, and the precision required to build a guard that actually does its job.
We work with WHW Plastics, one of the UK's leading suppliers of dental thermoforming materials, ensuring every blank that goes into your guard meets exacting material standards before the forming process even begins.
From digital scan to finished product, every step is controlled, measured, and quality-checked. That's what .PRO means.
Forming pressure
Digital scan time
Individually inspected
Compromise
Every guard we make is digitally scanned, pressure-laminated, individually measured, and quality-certified. From £75.