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Orthognathic occlusal setups: a comparative analysis of in-house and industry-generated splints
M F Caminiti1, S A Zahavi2, T Capucha1
1Oral and Maxillofacial Surgery Program, Faculty of Dentistry, University of Toronto, Toronto, Canada.
International Journal of Oral and Maxillofacial Surgery
|March 10, 2026
Summary
In-house fabricated surgical splints for orthognathic surgery resulted in significantly better occlusal outcomes compared to industry-produced splints. This demonstrates the viability of in-house fabrication for craniofacial surgery planning.
Area of Science:
- Oral and Maxillofacial Surgery
- Biomedical Engineering
- Orthodontics
Background:
- Advancements in 3D imaging, printing, and computer-assisted planning enable in-house surgical splint fabrication.
- This shift offers potential benefits in efficiency and data security for craniofacial surgery.
- Limited research exists comparing the quality of in-house versus industry-produced surgical splints.
Purpose of the Study:
- To compare the occlusal outcomes of in-house fabricated splints (IHS) versus industry-generated splints (IND) in orthognathic surgery.
- To evaluate the quality of splints produced in-house by oral and maxillofacial surgeons.
- To determine if in-house splints meet or exceed third-party industry standards.
Main Methods:
- Evaluation of 20 orthognathic surgery cases.
- Utilized 3D-printed dental models for splint fabrication and assessment.
- Employed a modified American Board of Orthodontics Objective Grading System for blinded orthodontist assessment of occlusions.
Main Results:
- In-house splints (IHS) achieved a significantly higher mean occlusal quality score (29.70) compared to industry splints (IND) (27.28) (P = 0.013).
- The results indicate superior occlusal outcomes with in-house fabricated splints.
- Blinded orthodontists rated the occlusions resulting from IHS as being of higher quality.
Conclusions:
- Oral and maxillofacial surgeons can produce in-house splints that meet or exceed industry standards after an initial learning curve.
- In-house fabrication is a highly effective and viable alternative for orthognathic surgical planning.
- In-house splint production offers significant clinical and logistical advantages for craniofacial surgery.
