Covestro Makrolon® polycarbonate delivers The Material Effect in new mouthguard designed for bruxism relief

Pittsburgh, PA, August 20,2026 – Bruxism, commonly known as teeth grinding, is one of the most common sleep disorders. It can lead to jaw pain, headaches or migraines, poor sleep, and long-term dental damage. Yet many who suffer from it stop wearing their mouthguard because it is too bulky, uncomfortable, or does not stay securely on their teeth. Guards made entirely of soft material can make the problem worse by promoting a chewing response that encourages further grinding.

Asesso Health Inc., set out to address these challenges with the G-Series Grind Guard. The device is an injection-molded, boil-and-press mouthguard, engineered specifically for moderate-to-severe bruxism and Temporomandibular Joint Disorder (TMD). At the core of the design is a polycarbonate splint, the rigid structural component that resists bite force and acts as the primary deterrent to grinding. The result is the only anatomically correct mouthguard on the market purpose-built for these conditions.

For the splint, Asesso Health selected Covestro's Makrolon® 2458 polycarbonate, a high productivity, injection-molding medical grade polycarbonate. The splint forms the structural backbone of the mouthguard, delivering the rigidity and bite-force resistance critical to discouraging grinding behavior. Makrolon® 2458 polycarbonate met all of Asesso Health’s functional requirements for moldability and medical-grade compliance, making it a natural fit for the G-Series' boil-and-press fitting process, in which the device is placed in boiling water before being custom-shaped to the user's teeth. This requirement significantly narrowed the field of candidate materials, as many medical-grade polymers cannot withstand repeated exposure to boiling water without warping, discoloring, or degrading. Makrolon® 2458 polycarbonate also provided the engineering documentation and supply chain maturity needed for a high-volume consumer healthcare product. The material was chosen after careful evaluation of all performance, regulatory, and manufacturing factors.

"We needed a medical-grade polycarbonate for the splint that could meet strict biocompatibility standards while performing reliably in a high-volume injection molding process," said Abhijit Limaye, Chief Product Officer, Asesso Health Inc. "The boil-and-press fitting process is central to our custom-fit experience, and that immediately ruled out a number of materials. Covestro's Makrolon® 2458 polycarbonate gave us confidence that the splint would maintain its dimensional stability to stay securely on the user’s teeth."

Covestro provided a comprehensive set of technical documentation that helped Asesso Health design the G-Series Grind Guard with confidence. Working alongside tooling and molding suppliers, Asesso was able to evaluate moldability, biocompatibility, and material hardness throughout the design and development process.

The G-Series Grind Guard is part of a broader connected-care platform from Asesso Health that pairs physical devices with a sensor module and mobile app, enabling users to monitor bruxism symptoms and track treatment progress over time. This approach reflects a growing trend across healthcare: combining advanced materials with digital tools to deliver more personalized, data-driven patient outcomes, even when individual device components are non-electronic. For Covestro, collaborations like this represent an expanding role for high-performance polymers within integrated care ecosystems.

"This is a strong example of The Material Effect and what happens when material science and technical support come together to solve a real, unmet need," said Emily Shaffer, Healthcare Market Manager, Americas-Engineering Plastics, Covestro LLC. "Makrolon® 2458 polycarbonate provided the performance and regulatory foundation that allowed Asesso Health to bring a truly differentiated product to market."

The G-Series Grind Guard is expected to be available for sale in the United States by mid-2026. International availability is planned at a later date, following completion of regulatory approvals.

Makrolon® 2458 polycarbonate is a high productivity, injection-molding medical grade polycarbonate suitable for various sterilization means, including steam sterilization at 121 °C. It is biocompatible according to many ISO 10993-1 test requirements and is available in transparent and opaque options.