Objectives: This study compared the accuracy of two software programs, Proplan CMF R 3.0.1 and Planmeca Romexis R 6.4.1, for fabricating occlusal repositioning wafers for bimaxillary orthognathic surgery.

Materials and Methods: Our research was conducted on 18 patients with skeletal deformities. Patients were randomly distributed into two groups: the control group, where 9 patients were planned by Proplan CMF R 3.0.1; and the study group, where 9 were planned by Planmeca R 6.4.1. All the patients underwent bimaxillary orthognathic surgery. Each patient received 2 CT scans preoperatively and 1 month postoperatively. Materialize 3-matic software was used to identify discrepancies between the virtual treatment plan and the outcome by superimposing the planned STL model with the postoperative one.

Results: The deviations measured with Romexis were slightly higher than those with Proplan. However, the results had no significant differences (p > 0.05). Both programs effectively fabricated splints accurately enough to transfer the virtual planning to the operation theater. The mean differences between the planned and postoperative positions of the maxilla and mandible were 0.37 and 0.48 mm.

Conclusion: This study supports the accuracy of both software programs (Proplan and Romexis) for splint fabrication for bimaxillary orthognathic surgery. However, further research is needed to refine software algorithms to reduce the observed minor variations.