Custom Mouthguards with Keystone: Laminates, EVA and Fun Guard Materials

The best materials for custom mouthguards from Keystone are the Pro-Form Mouthguard Laminates, a .160 (4mm) sheet made by laminating two layers of soft EVA, with Youth Mouthguard sheets for younger players and Fun Guard designs for athletes who want personality. Chase Dental Supply carries the full Keystone Industries mouthguard line, and this guide breaks down every option so your practice or lab can choose with confidence.

Key Takeaways

• Pro-Form Mouthguard Laminates bond two layers of soft EVA for excellent tensile strength at .160 (4mm).
• Youth Mouthguard sheets are .120 (3mm) soft EVA, thin enough for a child’s smaller mouth.
• Dual-Color, Tri-Color, Fun Guard and Tie Dye laminates let athletes match team colors and styles.
• Mouthguard Straps break away under less than 12 pounds of pressure for helmeted sports.
• The Centri-Fuse Kit adds logos and numbers without a second forming.

What Are Keystone Pro-Form Mouthguard Laminates?

Pro-Form Mouthguard Laminates are pre-made laminated mouthguard sheets made by bonding two layers of soft EVA together. Keystone states that Pro-Form manufactures the only pre-made laminated mouthguard material in the industry, and the lamination gives the sheet excellent tensile strength.

The standard Pro-Form Mouthguard Laminates are .160 (4mm) thick and come as 5×5 (127 x 127mm) squares or rounds in packs of 12. Solid colors include clear, orange, yellow, maroon, white, green, black, red, blue, purple and pink, plus assorted color packs.

EVA (ethylene vinyl acetate) is a soft, energy-absorbing thermoplastic that is the standard material for custom-formed athletic mouthguards. It forms cleanly on a vacuum former and trims easily with a heated knife.

Which Keystone Material Should I Choose for Custom Mouthguards?

Pick the material based on the athlete’s age, the look they want, and whether the guard needs a strap. Every option below is formed on a vacuum former from a 5×5 or round sheet.

Dual-Color and Tri-Color Laminates for team colors

The Pro-Form Dual-Color Mouthguard Laminate pairs two colors in a single .160 (4mm) laminated EVA sheet, in combinations such as black/white, blue/red and maroon/yellow. The Pro-Form Mouthguard Tri-Color Laminates offers three-color combinations like red/white/blue, white/green/black and purple/white/purple.

Fun Guard and Tie Dye designs

Pro-Form Fun Guard Mouthguards are made the same way as all Pro-Form laminates, in .160 (4mm) 5×5 sheets packed 12 per box. Styles include blue, white and red polkadots, Fang and Blood.

Pro-Form Tie Dye Mouthguards add tie dye patterns to the laminated line at .160 (4mm), in 5×5 or round sheets packed 6 per box. Both are popular with youth leagues and players who want a guard that stands out.

Youth Mouthguard sheets

Keystone Youth Mouthguard sheets are .120 (3mm) soft EVA, thin enough for the smaller mouth of a child who is just getting into sports. They come in 5×5 squares or rounds in packs of 25 or 300.

Mouthguard Resin Sheets

Keystone Mouthguard Resin Sheets are soft, single .160 (4mm) sheets designed for energy absorption. Keystone recommends them for both mouthguards and niteguards, packed 25 or 300 per box.

Laminates vs Resin Sheets vs Youth Sheets: What’s the Difference?

The differences come down to construction, thickness and pack size. This comparison uses the specifications Keystone publishes for each sheet.

How Do You Make a Custom Mouthguard with Keystone Materials?

You make a custom mouthguard by forming a heated EVA sheet over an accurate stone model on a vacuum former, then trimming, smoothing and fitting it. Always follow Keystone’s instructions for heat times and handling for each material.

• Pour a dense, accurate model. Our stone tips for pouring dental models cover the basics.
• Heat and form the sheet on a vacuum former such as the Keystone Machine III Vacuum Former. See our Keystone vacuum former buyer's guide to compare models.
• Cool the guard fully on the model before removing it.
• Trim the borders, smooth the edges, and check fit and comfort with the patient.

Customizing with the Centri-Fuse Kit

The Pro-Form Centri-Fuse Kit applies decals such as names, numbers and logos to a vacuum formed mouthguard without a second forming. A flameless torch fuses the material for clarity and adhesion while eliminating bubbles.

The kit includes 20 centri-fuse strips, a flameless torch, primer, brush, scissors, a trimming and polishing brush, and pre-printed decals. It is a straightforward way to meet athlete demand for personalized guards.

Adding a helmet strap

Keystone Mouthguard Straps attach to Pro-Form mouthguards for football, hockey, lacrosse and other helmeted sports. Their safety release lets the guard break away under less than 12 pounds of pressure, and they come in black or clear, 12 or 25 per pack.

When Does a Boil and Bite Guard Make Sense?

A boil and bite guard makes sense when a full custom guard is not practical, such as a team screening day or a last-minute request. The Keystone PF2 Boil and Bite Mouthguard is dual-laminated, boils to fit in under one minute, and is designed to fit like a custom guard.

It comes individually in solid black or white. For athletes who also grind at night, a separate night guard is a better fit, which we cover in our guide to night guards and splints.

Shop the Products

Frequently Asked Questions

What is the best material for a custom sports mouthguard?

For most athletes, a laminated EVA sheet such as Pro-Form Mouthguard Laminates at .160 (4mm) is the standard choice. Keystone laminates two layers of soft EVA together for excellent tensile strength, and single-layer Keystone Mouthguard Resin Sheets at the same thickness offer soft, energy-absorbing protection.

What thickness should a youth mouthguard be?

Keystone makes its Youth Mouthguard sheets at .120 (3mm), thin enough to fit a child’s smaller mouth while the soft EVA still absorbs energy. Adult and competitive athletes typically use the .160 (4mm) laminates and resin sheets. The treating dentist should choose the final thickness for each patient.

What is the difference between Pro-Form laminates and resin sheets?

Pro-Form Mouthguard Laminates are made by laminating two layers of soft EVA together, which gives excellent tensile strength and allows two-color and three-color designs. Keystone Mouthguard Resin Sheets are soft, single sheets for energy absorption and can be used for both mouthguards and niteguards. Both are .160 (4mm) thick and come in 5×5 squares or rounds.

How do you add a logo or number to a custom mouthguard?

The Pro-Form Centri-Fuse Kit applies decals to a vacuum formed mouthguard without a second forming. It uses a flameless torch to fuse centri-fuse strips for clarity and adhesion without bubbles, and the kit includes strips, torch, primer, brush, scissors, a trimming and polishing brush, and pre-printed decals.

What is the PF2 Boil and Bite Mouthguard?

The Keystone PF2 is a dual-laminated boil and bite mouthguard that Keystone designed to fit like a custom guard. It can be boiled and fitted in under one minute and comes individually in solid black or white. It is a practical option when a full custom guard is not possible, such as team events or walk-in requests.

Explore every brand we carry in our dental lab and office supply brands guide. Chase Dental Supply stocks Keystone Industries mouthguard materials in the colors, thicknesses and pack sizes busy sports dentistry programs need. Questions about color availability or lead times? Email sales@chasedentalsupply.com.