ABSTRACT Introduction This technical report details a streamlined hybrid protocol designed to address the implementation gap between conventional mechanical articulators and virtual articulation systems (VAS). The study aimed to develop a hardware-independent method to accurately transfer a patient’s unique spatial orientation from a conventional facebow record to a digital environment. Methods The workflow utilizes diagnostic casts previously mounted on a semi-adjustable mechanical articulator. A standardized vertical distance of 50 mm was established to create a three-point reference triangulation on the mandibular diagnostic cast. The marked cast was digitized using a color-capable intraoral scanner (IOS) and exported in Polygon File Format (PLY) to preserve the color data of the markers. Within computer-aided design (CAD) software, a point-based alignment was performed to orient the digitized diagnostic casts, replicating the maxillomandibular relationship established in the conventional setup. Results The results demonstrated that the proposed protocol accurately maintained the spatial orientation of the maxillary arch relative to the mandibular axis. Visual verification within the VAS confirmed that the digital occlusal contacts faithfully mirrored those observed on the physical casts, ensuring transfer accuracy without the need for specialized facial scanning hardware. Conclusions The described hybrid approach provides an effective and accessible alternative for clinicians. It facilitates the integration of digital tools into contemporary prosthodontic practice by leveraging the time-tested accuracy of conventional mounting procedures while utilizing the advanced diagnostic capabilities of CAD technology. Clinical Significance This report offers a practical pathway to transfer conventional facebow records to a VAS, providing an accessible solution for clinicians to transition to digital workflows without immediate investment in specialized jaw-tracking or facial scanning equipment.
Roeder et al. (Fri,) studied this question.