Digital Twin Block Appliance: Precision And Clinical Advantages

This comparative study evaluates the occlusal accuracy and clinical efficacy of digitally fabricated versus conventionally manufactured Twin Block appliances, aiming to establish evidence-based recommendations for implementing digital workflows in orthodontic practice. Ten patients in mixed or early permanent dentition (five males, five females) were enrolled. Intraoral scans were used to create virtual articulator models and 3D-printed gold standard models. Digital TBs were designed in OG-DOS and 3D printed, while conventional TBs were fabricated using wax bite registration, plaster models, and conventional techniques. Data collection included 3D scanning for misfit analysis (vertical and horizontal), weight measurement for material efficiency, and time recording for process efficiency. 3D Scanning Errors: Digital TBs showed smaller errors (0.12–0.18 mm in anterior vertical fit, -0.08 to -0.13 mm in mandibular horizontal fit) compared to conventional TBs (0.47–0.78 mm vertically, -0.307 to -0.62 mm horizontally), indicating superior precision. Weight Analysis: Digital TBs had lower pre-polishing weights (13.2–14.8 g) than conventional TBs (16.5–18.4 g), highlighting better material efficiency. Time Efficiency: Digital fabrication took 38–45 minutes, significantly faster than conventional methods (66–72 minutes). Digital TB fabrication offers advantages in precision and efficiency compared with conventional method. Such a method minimize errors and material waste while restoring occlusal relationships accurately. Its clinical benefits enable it suitable for widespread adoption. As digital technology advances, its role in orthodontics is expected to expand for enhancing treatment outcomes and patient satisfaction.