How accurate are rapid prototyped (RP) final orthognathic surgical wafers? A pilot study

Computer packages have been introduced to simulate the movements of the jaw in three dimensions to facilitate planning of treatment. After final 3-dimensional virtual planning, a rapid prototype wafer can be manufactured and used in theatre. Our aim was to assess the accuracy of rapid prototyping of virtual wafers derived from laser scanned dental models using CAD/CAM software. Upper and lower plaster models from 10 orthognathic patients, the articulated models, and the conventional wafers were scanned. The virtual wafers were made from CAD/CAM software, and printed on a stereolithographic printer. We also scanned the articulated models with rapid prototype wafers in place. The validity of the final rapid prototype wafer was measured by the accuracy with which upper and lower models related to one another. The absolute mean error of the rapid prototype wafer when aligned with the dental models was 0.94 (0.09) mm. The absolute distance of the 2 models articulated by conventional and rapid prototype wafers ranged from 0.04 - 1.73mm. The rapid prototype wafers were able to orientate the upper and lower dental models with an absolute mean error of 0.94 (0.09) mm, but it ranged from 0.04-1.73mm.