New protocol for three-dimensional surgical planning and CAD/CAM splint generation in orthognathic surgery: an in vitro and in vivo study

Inaccurate visualization of the inter-occlusal relationship has raised an important challenge to virtual planning for orthognathic surgery based on cone beam computerized tomography (CBCT). The aim of this study was to evaluate an innovative workflow for orthognathic surgery planning and surgical splint fabrication. The clinical protocol consists of a single cone beam computerized tomography (CBCT) scan of the patient, surface scanning of the dental arches with an intraoral digital scanner, and subsequent fusion of the two datasets. The “virtual patient” thus created undergoes virtual surgery, and the resulting file with the intermediate intermaxillary relationship is used to obtain the intermediate splint by CAD/CAM technology (computer-aided design and computer-aided manufacturing). A proof-of-concept study was performed in order to assess the accuracy and reliability of this protocol. The study comprised two parts: an in vitro evaluation on three dentate skull models and a prospective in vivo assessment on six consecutive patients. Vector error calculation between the virtually simulated intermaxillary position and the intraoperative intermediate intermaxillary relationship revealed high accuracy. The greatest average variation corresponded to the y axis. Compared to previously described methods for obtaining an augmented three-dimensional virtual model, this procedure eliminates the need for dental impressions, simplifies the necessary technical steps and computational work, and reduces the patient's exposure to ionizing radiation.