Digital Workflow for the Fabrication of a Carbon Fiber Face Guard to Prevent Orofacial Trauma: An overview and Case Report

Abstract

Face guards effectively reduce the risk of facial injuries in athletes. This study aimed to present a case report and discuss the scientific literature on facial trauma in sports and innovations in the fabrication of face guards. Global regulatory disparities and the importance of education in promoting the use of protective equipment are key factors for injury prevention. Conventionally, alginate impressions have been widely used in manufacturing processes. However, the implementation of digital workflows involving photogrammetry and three-dimensional printing offers a promising alternative for fabricating customized face guards. Various materials have been used for fabricating the outer layer of face guards, with carbon fibers standing out for their ability to enhance both protection and comfort. These findings suggest that digital innovations and custom designs can improve athlete safety and increase comfort and confidence, thereby contributing to a safer sports environment.