A digital technique for fabricating a diagnostic occlusal device using mandibular motion tracking

To present a fully digital process for creating diagnostic occlusal devices through intraoral scanning and digital tracking of mandibular movements. A clinical approach was adopted involving intraoral scanning of dental arches in maximum intercuspation. A second maxillary scan, performed with a modified fork, was imported into software for digital facebow transfer. The prosthetic plane was recorded in the natural head posture using a central marker. Lateral markers were applied on the canines, and mandibular movements were tracked with an optical axiograph. Functional motions, including opening, closing, excursions, and mastication, were analyzed to identify the optimal position. This position was then exported into CAD software for articulator configuration and splint design. The final device was milled in polymethyl methacrylate and clinically evaluated. The digital workflow provided stable and reproducible mandibular recordings. The diagnostic position differed from maximum intercuspation by 3.8 mm anteriorly and 9 mm vertically. The digitally fabricated splint showed excellent fit without the need for occlusal adjustments. Follow-up motion tracking confirmed functional alignment. The patient reported no discomfort or occlusal interferences. This technique allows for the precise fabrication of diagnostic occlusal devices by integrating dynamic mandibular data into the design process, improving clinical accuracy.