Over the past 100 years, there has been considerable research published about the causes of orthodontic and jaw joint (TMJ) problems. Dr Chris Farrell discovered that most of these causes relate to incorrect breathing and swallowing, also known as incorrect myofunctional habits. Unfortunately, the majority of the dental and medical professionals in the 1980s did not know or did not accept this research, although the majority of children in any population had a developing malocclusion and many adults suffered pain from TMJ disorders. These widespread disorders were not being adequately treated because of the lack of knowledge and resources. Dr Chris Farrell decided to address the treatment of these problems using intraoral appliances with appropriate design characteristics built into each universally-fitting model. This would allow many more patients access to this treatment and would allow both doctors and trained auxiliaries to perform this type of treatment in a more efficient manner than was previously possible.

Computer-aided design (CAD) technology was in its infancy in 1989 and no intraoral dental appliances had yet used this technology. However, CAD technology served as a crucial part of the development of MRC's products.

Since 1991, the products have been introduced into the dental and medical professions, beginning with Australia and New Zealand. Though, considerable time was needed to acquire the necessary government approvals to expand into other countries. By 1993, FDA approval for the USA and Europe had been granted, allowing the educational process to commence on a wider scale. Japan, South East Asia and South America followed in subsequent years. Dr Farrell and Dr Flutter lectured extensively in these countries to illustrate the advantages of the new Trainer and TMJ systems.

Although the concepts were not new, acceptance within the professions has been slower than expected, sometimes due to insufficient knowledge of the subject and/or political resistance. At the present time, the products have overcome many of these barriers and are now being used in more than 100 countries throughout Europe, the Americas and in Asia. 

In the process of researching the subject of temporomandibular joint (TMJ) dysfunction and malocclusion, an underlying commonality was found between the causes of these two diseases. Research into myofunctional issues appeared to be most neglected in orthodontic and TMJ treatment methods. The more Dr Farrell researched myofunctional problems in his patients, the more he realised that a new approach to treatment was necessary.

Crowded teeth were not caused by big teeth and small jaws inherited from parents. Clenching and grinding of the teeth did not cause jaw problems. The causes were all myofunctional and could be treated with a myofunctional philosophy and technique.

The lack of knowledge within the profession in this area was hampering the treatment of the disorders and many held widely differing opinions. Extensive myofunctional research and clinical experience combined with the latest CAD facilities at the time (1990) meant it was possible to produce universal-size, intraoral appliances that had therapeutic characteristics to influence the oral musculature and subsequently treat patients myofunctionally.

The CAD design facilities from the Queensland University of Technology (QUT) and The Queensland Manufacturing Institute were paramount in the development of MRC's appliances and treatment methods.

The first product produced by MRC was The TMJ Appliance^®. This allowed the medical and dental professions to diagnose and treat TMJ disorder quickly and effectively. The area of orthodontics was the next to be addressed with the Pre-orthodontic Trainer, which assisted in improving poor myofunctional habits while providing tooth guidance to correct malocclusion in the growing child. The following Trainer for Braces, Trainer for Alignment, Trainer for Function and Trainer for Universal were introduced as logical steps in improving treatment stability, reducing treatment time, and lessening the need for extractions.

Dr Chris Farrell moved his attention to sports mouthguards in 1998. Retail mouthguards were often of poor fit and provided very little protection. Custom-made mouthguards from a dentist were inconvenient and prohibitively expensive at the time. Applying the same CAD technology as used in the TMJ and orthodontic appliances, Dr Farrell produced the most advanced mouthguard range for the retail market. These mouthguards were introduced into the North American market under the Shock Doctor brand and additionally as Powrgard® in Europe and Australia.