Abstract
Objective: To present a fully digital workflow for fabricating diagnostic occlusal devices using intraoral scanning and digital mandibular motion tracking. Methods: A clinical method was applied involving intraoral scanning of dental arches in maximum intercuspation. A second maxillary scan, using a rebased fork, was imported into a software for digital facebow transfer. The prosthetic plane was recorded in natural head posture using a central marker. Lateral markers were placed on canines, and mandibular movements were recorded with an optical axiograph. Functional motions, including opening, closing, excursions, and mastication, were analyzed to determine the utility position. This position was exported into CAD software for articulator configuration and splint design. The final device was milled in PMMA and assessed clinically. Results: The digital workflow provided stable, 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. Conclusions: This technique allows for the accurate fabrication of diagnostic occlusal devices by integrating dynamic mandibular data into the design process, improving clinical precision. Clinical significance: By capturing functional mandibular movements digitally, this workflow enhances diagnostic reliability, minimizes chairside adjustments, and supports prosthetic planning based on real jaw dynamics.