Abstract: PURPOSE: Rapid prototyping(RP) technology was employed to make high quality 3-dimensional head simulator, which was then precisely combined with a fine plaster cast of dental arch by facebow for model surgery to guide surgery-first-orthodontic-approach for maxillofacial asymmetry and evaluate the effect. METHODS: Five patients with dento-maxillofacial deformities underwent spiral CT scan to collect raw data, which were then inputted into rapid prototyping machine to generate 3-dimensional head-simulators. The plaster casts of dental arch were subsequently replaced with those of 3-dimensional head-simulators in the same ratio. Finally, high simulation dental craniofacial models were formed for simulating osteotomy prior to surgery, in order to assess the position and volume of osteotomy, the symmetry of chin and variation of temporomandibular joint (TMJ), and surgical effect 6 months after operation. RESULTS: High simulation dental craniofacial models from 5 patients were shown to be good for predicting the effect of surgery. The 6-month follow-up results showed the patients were satisfied with their appearances without complications including TMJ disorder. CONCLUSIONS: High simulation dental craniofacial model is valuable in precisely simulating osteotomy, contributing to understand surgery-first-orthodontic-approach for maxillofacial asymmetrical patients.

Key words: Rapid prototyping technology, High simulation dental craniofacial model, Surgery-first-orthodontic-approach, Maxillofacial asymmetry