Evaluation of the Trueness and Precision of a Simplified Method for Transferring the Relationship of the Maxillary Plane and Transverse Hinge Axis to Virtual Articulators

Background The digital transfer of data for establishing the maxillary occlusal plane and condylar path aims for high precision, facilitating accurate use of virtual articulators and aiding in digital prosthetic fabrication. Objective This study evaluates the accuracy of transferring maxillary scans to a virtual articulator using a novel customized transfer tool compared to a conventional facebow system. Methods Three types of master models, bilateral balanced, monoplane, and lingualized occlusion, were prepared and duplicated. Landmarks on the maxillary and mandibular models were identified, and interlandmark distances served as controls. The models were scanned intraorally, and virtual bite alignment was performed using a best‐fit algorithm. A manual facebow transfer defined the occlusal and condylar relationships on a mechanical articulator, which was then transferred to a virtual articulator via the customized transfer tool and computer‐aided design (CAD) software. Transfer accuracy was assessed by comparing interlandmark distances between mechanical and virtual setups using statistical tests (Shapiro–Wilk, Levene’s, and t ‐tests) at α = 0.05. Reliability was evaluated with the intraclass correlation coefficient (ICC). Results No significant differences were found between the mechanical and virtual interlandmark distances across all models ( p > 0.05). Differences ranged from −0.08 to 0.11 mm, within clinically acceptable limits. ICC values exceeded 0.80, indicating high reliability of the transfer method. Conclusions The customized transfer tool accurately transferred maxillary occlusal plane and condylar path relationships to the virtual articulator, with no significant discrepancies observed.