Orthognathic occlusal setups: a comparative analysis of in-house and industry-generated splints

Three-dimensional imaging, 3D printing, and computer-assisted planning have revolutionized craniofacial surgery, allowing surgeons to fabricate surgical splints in-house. While this shift enhances efficiency and data security, research comparing the quality of in-house versus industry-produced splints remains limited. This study evaluated 20 orthognathic surgery cases to compare industry-generated splints (IND) with in-house-fabricated splints (IHS). Using 3D-printed dental models and a modified American Board of Orthodontics Objective Grading System, two blinded orthodontists assessed the resulting occlusions. Higher scores indicated superior occlusal quality. The results demonstrated that in-house splints (mean score 29.70) yielded significantly better occlusal outcomes than industry splints (mean score 27.28) (P = 0.013). This suggests that, following an initial learning curve, oral and maxillofacial surgeons can produce in-house splints that meet or exceed the quality of third-party industry standards. In-house fabrication serves as a highly effective, viable alternative for orthognathic surgical planning, offering clinical advantages alongside logistical benefits.