Digitally planned bimaxillary orthognathic surgery with 3D-printed splints for skeletal class III malocclusion: A...

This retrospective, single-center, non-consecutive case series explores the outcomes of digitally planned bimaxillary orthognathic surgery using three-dimensional (3D) printed surgical splints in the treatment of skeletal class III malocclusion.

Three adult male patients who underwent combined orthodontic-orthognathic treatment at a private orthodontic center between January 2022 and June 2024 were included nonconsecutively. Presurgical orthodontic preparation was undertaken to decompensate the incisors, align the dental arches, and create optimal conditions for precise skeletal corrections.

The diagnoses were class III malocclusions on skeletal class III bases with varying vertical facial patterns.

Surgical planning incorporated advanced 3D technologies, including multi-slice computed tomography and computer-aided design, to customize surgical movements and fabricate splints via digital light processing 3D printing.

Postoperatively, significant improvements were observed in facial aesthetics, occlusion, and skeletal symmetry. Class I occlusion with aligned dental midlines was achieved in all patients. Although slight reductions in upper airway volume were noted in 2 cases, no functional impairments or obstructive sleep apnea symptoms occurred. The use of 3D-printed splints facilitated accurate surgical execution, particularly in complex movements requiring multi-plane adjustments.

This case series highlights the benefits of integrating 3D printing technology with digital surgical planning to enhance precision, efficiency, and clinical outcomes in bimaxillary orthognathic surgery. The findings emphasize the importance of combining advanced fabrication methods with tailored treatment protocols to achieve functional and aesthetic goals in patients with skeletal class III malocclusion.