A novel approach for planning orthognathic surgery: the integration of dental casts into three-dimensional printed mandibular models

A method of producing a composite model consisting of a three-dimensional printed mandible bearing plaster teeth is presented. Printed models were obtained from cone beam computed tomograms (CBCT) of dry human mandibles. The plaster casts of the teeth were obtained from impressions of the teeth of the dry mandibles. The distorted teeth of the printed models were removed and replaced by the plaster casts of the teeth using a simple transfer jig. The accuracy of the composite models obtained from six mandibles was assessed from laser scans. The scans of the dry mandibles and the composite models were superimposed and the magnitude of the discrepancies at six points on the dentition and six on the mandible were obtained. It was concluded that the errors of the method were small enough to be clinically significant. The use of the composite models is illustrated in two clinical cases.