Tapping the potential of rapid prototyping techniques in creating a paradigm shift in the fabrication of occlusal splints

Purpose This study aims to cover the overall gamut of rapid prototyping processes and biomaterials used for the fabrication of occlusal splints in a comprehensive manner and elucidate the characteristics of the materials, which are essential in determining their clinical efficacy when exposed to oral surroundings. Design/methodology/approach A collective analysis of published articles covering the use of rapid prototyping technologies in the fabrication of occlusal splints, including manufacturing workflow description and essential properties (mechanical- and thermal-based) evaluation of biocompatible splinting materials, was performed. Findings Without advances in rapid prototyping processes and materials engineering, occlusal splints would tend to underperform clinically due to biomechanical limitations. Social implications Three-dimensional printing can improve the process capabilities for commercial customization of biomechanically efficient occlusal splints. Originality/value Rapid technological advancement in dentistry with the extensive utilization of rapid prototyping processes, intra-oral scanners and novel biomaterial seems to be the potential breakthrough in the fabrication of customized occlusal splints which have endorsed occlusal splint therapy (OST) as a cornerstone of orthodontic treatment.