A digital process for additive manufacturing of occlusal splints: a clinical pilot study

Abstract

The aim of this study was to develop and evaluate a digital process for manufacturing of occlusal splints. An alginate impression was taken from the upper and lower jaws of a patient with temporomandibular disorder owing to cross bite and wear of the teeth, and then digitized using a table laser scanner. The scanned model was repaired using the 3Data Expert software, and a splint was designed with the Viscam RP software. A splint was manufactured from a biocompatible liquid photopolymer by stereolithography. The system employed in the process was SLA 350. The splint was worn nightly for six months. The patient adapted to the splint well and found it comfortable to use. The splint relieved tension in the patient's bite muscles. No sign of tooth wear or significant splint wear was detected after six months of testing. Modern digital technology enables us to manufacture clinically functional occlusal splints, which might reduce costs, dental technician working time and chair-side time. Maximum-dimensional errors of approximately 1 mm were found at thin walls and sharp corners of the splint when compared with the digital model.

Figure 1.

The process for planning and additive manufacturing of occlusal splints. The dashed line defines the digital steps of the process.

Figure 2.

The patient's dentition. (Online version in colour.)

Figure 3.

The three-dimensional model of the occlusal splint.

Figure 4.

The occlusal splint in use.

Figure 5.

The occlusal splint after test period. (Online version in colour.)

Figure 6.

The accuracy, wear and the trim needed can be assessed when comparing the used splint with the designed three-dimensional model.