3D Printed Occlusal Splint in 60 Minutes – A Fully Digital Workflow
Published in Quintessenz Zahntechnik, May 2026: https://www.quintessence-publishing.com/deu/de/journal/quintessenz-zahntechnik/2026/05
Producing an occlusal splint in as little as 60 minutes—without a physical model, articulator, or extensive occlusal adjustment—may sound ambitious. Yet, advances in digital dentistry have made this approach a routine part of clinical practice.
Among the many applications of digital dentistry, occlusal splint fabrication clearly demonstrates the advantages of a fully digital workflow. Conventional methods rely on impressions, model fabrication, mechanical articulation, and flasking procedures, whereas digital workflows streamline the process while improving precision, efficiency, and reproducibility.
The following clinical case highlights how 3D printing is redefining occlusal splint fabrication and why it is increasingly considered a benchmark for modern splint therapy.
Indication: Bruxism
The patient had a documented history of nocturnal bruxism and complained of muscular tension upon waking. Clinical examination revealed wear facets on the posterior teeth as well as tenderness of the masseter muscles, confirming the indication for a maxillary occlusal splint.
Whereas splints in our practice were previously fabricated using conventional techniques—including analog impressions, model fabrication, mechanical articulation, and heat-polymerized acrylic resin—we now follow a fully digital workflow. In this approach, the splint is produced directly from digital intraoral scan data, eliminating the need for analog intermediate steps.
From Scan to Splint – The Digital Workflow
Precision Begins with Data Acquisition
Digital impressions of the maxillary and mandibular arches were captured with an intraoral scanner. Obtaining reliable scan data requires standardized acquisition conditions, including correct scanner positioning, deactivated dental chair lighting, and minimizing mandibular movement throughout the scanning procedure.
Current intraoral scanning systems generate high-resolution three-dimensional models of the dentition in real time, providing the foundation for an entirely digital workflow.
The maxillomandibular relationship in physiological centric relation was recorded using bite registration silicone and transferred to the digital dataset (Figs. 1 and 2), eliminating the need for conventional mechanical articulation.
An important advantage of the digital workflow is the ability to validate scan data immediately. Any defects or scanning artifacts can be detected and corrected before the design and manufacturing process begins (Figs. 4 and 5). Once the digital records have been verified, they can be transferred directly to CAD planning and additive manufacturing without requiring any analog intermediate steps.
Additive Manufacturing Using DLP Technology
The occlusal splint was manufactured using a Rapid Shape PRO 20 DLP 3D printer in combination with the coordinated WASH and CURE units (Fig. 5).
Positioning the splints vertically on the build platform (Fig. 6) reduces the number of support structures in functional areas while enhancing surface quality. This setup also enables the production of up to six splints on a single build platform in approximately 90 minutes.
In contrast to conventional manufacturing methods, the digital workflow eliminates the need for a physical working model. Thanks to the high dimensional accuracy achieved by DLP printing, the splint can often be inserted directly with little or no occlusal adjustment.
Crystal Polish Technology
A key feature of the system is the use of dedicated resin vats designed for the Crystal Polish process (Fig. 7).
When combined with RS VIVO Splint Hard material, the process produces splints with an almost high-gloss surface directly after printing. As a result, the amount of post-processing and manual polishing is significantly reduced while maintaining excellent surface quality.
Material Properties and Biocompatibility
A biocompatible, methacrylate-based resin (RS VIVO Splint Hard) was selected for manufacturing the occlusal splint.
Key material properties include:
- Very low solubility (≈ 1.1 µg/mm³)
- High toughness combined with controlled elasticity
- Excellent polishability
- ISO-certified biocompatibility
The material’s low solubility contributes to reduced residual monomer release while supporting odor and taste neutrality. In addition, the validated polymerization process achieved through the coordinated WASH and CURE units ensures a defined final curing state, which is essential for the biological safety of intraoral dental appliances.
Clinical Outcome
The fabricated splint was inserted directly after completion of the printing and post-processing workflow. Clinical evaluation showed the following results:
- Precise, stress-free fit
- Reliable retention
- Balanced occlusal contacts
- Minimal requirement for adjustments
Additional extensive manual finishing was not necessary. The patient reported a high level of comfort and good acceptance of the splint during use.
Discussion
The conventional fabrication process—including impression taking, model creation, articulation, and polymerization—is subject to multiple potential sources of cumulative error. Factors such as material expansion, polymerization shrinkage, and manual occlusal adjustments may negatively influence the final accuracy of the splint.
Digital workflows replace these variable steps with a standardized, data-driven process chain. Modern intraoral scanners provide clinically reliable accuracy, while additive DLP manufacturing enables consistent production with optimized material efficiency.
An additional advantage is the ability to validate and document the complete manufacturing workflow. With increasing regulatory demands in dentistry, standardized and traceable production processes are becoming an increasingly important aspect of modern digital treatment concepts.
Conclusion
The integration of digital data acquisition with additive DLP manufacturing enables the accurate, reproducible, and cost-efficient production of adjusted occlusal splints.
Therefore, the 3D printed occlusal splint represents more than a technological advancement; it reflects a logical progression toward standardized, quality-controlled manufacturing processes in contemporary splint therapy.
Frequently Asked Questions About 3D Printed Occlusal Splints & Digital Workflow
How long does it take to 3D print an occlusal splint?
With a fully digital DLP workflow, a 3D printed occlusal splint can be fabricated in approximately 60 minutes — without impressions, models, or manual articulation. Up to six splints can be produced on a single build platform within approximately 90 minutes.
What material is used for 3D printed occlusal splints?
RS VIVO Splint Hard is a biocompatible methacrylate-based resin with ISO-certified biocompatibility, high toughness, controlled elasticity, and very low solubility (≈1.1 μg/mm³), ensuring odor and taste neutrality for intraoral use.
What is Crystal Polish technology in dental 3D printing?
Crystal Polish is a Rapid Shape process using dedicated resin vats that produces a near high-gloss finish directly from the printer — significantly reducing post-processing time without compromising surface quality.
Is DLP 3D printing more accurate than conventional occlusal splint fabrication?
Yes. The 3D printed occlusal splint digital workflow eliminates cumulative analog errors such as polymerization shrinkage, material expansion, and manual occlusal adjustments, resulting in higher reproducibility, better fit, and a standardized, fully documentable manufacturing process.
Can a 3D printed occlusal splint be inserted directly without adjustment?
In many cases, yes. The dimensional accuracy of DLP-printed splints allows direct insertion with minimal or no occlusal grinding — a significant advantage over conventionally fabricated splints that typically require extensive manual finishing.
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