Technical Note Orthognathic Surgery| Volume 50, ISSUE 8, P1075-1077, August 2021

Efficient in-house 3D printing of an orthognathic splint for single-jaw cases

  • W. Mascarenhas
    Address: Wendall Mascarenhas, Division of Oral and Maxillofacial Surgery, McGill University, 1650 Cedar Avenue, Montreal, QC, H3G 1A5, Canada. Tel: +1 704 957 7929; Fax: +1 514 934 8340
    Division of Oral and Maxillofacial Surgery, Faculty of Dentistry, McGill University, Montreal, Québec, Canada
    Search for articles by this author
  • N. Makhoul
    Division of Oral and Maxillofacial Surgery, Faculty of Dentistry, McGill University, Montreal, Québec, Canada

    Department of Dentistry and Oral and Maxillofacial Surgery, McGill University Health Centre, Montreal, Québec, Canada
    Search for articles by this author
Published:January 11, 2021DOI:


      The purpose of this paper is to outline a simple and effective digital protocol for in-house 3D-printing of orthognathic splints for use during single-jaw orthognathic surgery. Using this protocol, an intraoral scanner, and virtual planning software, computer-designed splints were fabricated by a rapid prototyping machine in-house. The protocol was utilized for 35 consecutive patients requiring single-jaw orthognathic surgery between January 2019 and March 2020. The total time from initial scan to splint fabrication for each case was between 5 and 9 hours, including 3 minutes for scanning of models, 4.5 minutes for development of the splint, and 4–8 hours for rapid prototyping and post-processing. This time varied based on the complexity of the design and the number of splints printed simultaneously. The average cost of raw materials for each splint was $0.73 Canadian dollars.

      Key words

      To read this article in full you will need to make a payment

      Purchase one-time access:

      Academic & Personal: 24 hour online accessCorporate R&D Professionals: 24 hour online access
      One-time access price info
      • For academic or personal research use, select 'Academic and Personal'
      • For corporate R&D use, select 'Corporate R&D Professionals'


      Subscribe to International Journal of Oral and Maxillofacial Surgery
      Already a print subscriber? Claim online access
      Already an online subscriber? Sign in
      Institutional Access: Sign in to ScienceDirect


        • Xia J.J.
        • Gateno J.
        • Teichgraeber J.F.
        Three-dimensional computer-aided surgical simulation for maxillofacial surgery.
        Atlas Oral Maxillofac Surg Clin North Am. 2005; 13: 25-39
        • McCormick S.U.
        • Drew S.J.
        Virtual model surgery for efficient performance.
        J Oral Maxillofac Surg. 2011; 69: 638-644
        • Sharifi A.
        • Jones R.
        • Ayoub A.
        • Moos K.
        • Walker F.
        • Khambay B.
        • McHugh S.
        How accurate is model planning for orthognathic surgery?.
        Int J Oral Maxillofac Surg. 2008; 37: 1089-1093
        • Zhang N.
        • Liu S.
        • Hu Z.
        • Hu J.
        • Zhu S.
        • Li Y.
        Accuracy of virtual surgical planning in two-jaw orthognathic surgery: comparison of planned and actual results.
        Oral Surg Oral Med Oral Pathol Oral Radiol. 2016; 122: 143-151
        • Hsu S.S.
        • Gateno J.
        • Bell R.B.
        • Hirsch D.L.
        • Markiewicz M.R.
        • Teichgraeber J.F.
        • Zhou X.
        • Xia J.J.
        Accuracy of a computer-aided surgical simulation protocol for orthognathic surgery: a prospective multicenter study.
        J Oral Maxillofac Surg. 2013; 71: 128-142
        • Kwon T.G.
        • Choi J.W.
        • Kyung H.M.
        • Park H.S.
        Accuracy of maxillary repositioning in two-jaw surgery with conventional articulator model surgery versus virtual model surgery.
        Int J Oral Maxillofac Surg. 2014; 43: 732-738
        • Resnick C.M.
        • Inverso G.
        • Wrzosek M.
        • Padwa B.L.
        • Kaban L.B.
        • Peacock Z.S.
        Is there a difference in cost between standard and virtual surgical planning for orthognathic surgery?.
        J Oral Maxillofac Surg. 2016; 74: 1827-1833
        • Steinhuber T.
        • Brunold S.
        • Gartner C.
        • Offermanns V.
        • Ulmer H.
        • Ploder O.
        Is virtual surgical planning in orthognathic surgery faster than conventional planning? A time and workflow analysis of an office-based workflow for single- and double-jaw surgery.
        J Oral Maxillofac Surg. 2018; 76: 397-407
        • Farrell B.B.
        • Franco P.B.
        • Tucker M.R.
        Virtual surgical planning in orthognathic surgery.
        Oral Maxillofac Surg Clin North Am. 2014; 26: 459-473