Record Extent and Occlusal Support in Scan-Assisted Interocclusal Registration: A Three-Dimensional In Vitro Study

Scan-assisted interocclusal registration may vary with record extent and occlusal support. Using separately fabricated high-hardness vinyl polysiloxane (VPS) records, a fixed bilateral buccal intraoral scanner (IOS) acquisition protocol, optical reference articulations, and position-level three-dimensional analysis, this in vitro study compared prepared-tooth (Hard-Prep) and complete-arch (Hard-Arch) records across three support configurations and assessed a no-record IOS workflow. Ninety VPS-based and 45 no-record IOS acquisitions were analyzed. VPS records were fabricated under a 3.0 kg load; measurements used a 1.0 kg load. Overall three-dimensional deviation (dXYZ) was averaged over five mandibular positions. Log-transformed dXYZ was analyzed by ordinary least squares with Holm-adjusted contrasts. The Hard-Arch/Hard-Prep contrast was not statistically significant under bilateral extended support. Hard-Arch showed higher dXYZ under unilateral extended support (ratio, 1.75; 95% confidence interval (CI), 1.54–1.99; p < 0.001) and unilateral limited support (ratio, 1.58; 95% CI, 1.39–1.80; p < 0.001). In the no-record workflow, unilateral extended support exceeded bilateral extended support (ratio, 1.50; 95% CI, 1.31–1.72; p < 0.001), whereas unilateral limited support was lower than unilateral extended support (ratio, 0.68; 95% CI, 0.59–0.77; p < 0.001). Prepared-tooth records yielded lower deviation in both unilateral configurations, while the no-record workflow varied with support configuration.