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1. INTRODUCTION An occlusal splint is a custom fabricated hard acrylic device that fits over the occlusal and incisal surface of maxillary or mandibular teeth. Occlusal splints represent the main therapeutic option for patients suffering from temporomandibular disorders (TMDs) and bruxism. 1 Its principle use is to prevent the patient from finding his usual occlusion of maximal intercuspal position (ICP) and to oblige him to place his mandible in a new posture, thus, resulting in a new muscular and articular balance.3 Occlusal splints must withstand occlusal forces, be aesthetically pleasing and comfortable. Occlusal splints are conventionally made with self-cure or heat cure acrylic resin. But a great quantity of residual monomer and polymerization shrinkage can influence the mechanical properties of occlusal splints and decrease their clinical performance.2 The materials used in fabrication of occlusal splints must have adequate occlusal stability to withstand applied loads in the oral environment without changing their mechanical properties.2 In the human dentition, the mean occlusal forces range from 107 to 156 N (10 kg to 15kg).4 During parafunctional habits, these forces can reach upto 794 N (81.2 kg). 5Recently, digitally supported fabrication processes such as Computer-aided design/Computer-aided manufacturing (CAD/CAM) has allowed the usage of Subtractive technology (Milling) and Additive technology (3D-printing) and has given rise to an improvement in materials used in fabrication of occlusal splints. CAD/CAM Milling is well known in the field of dentistry and so is the reason it is studied widely. Whereas studies on 3D printing still remains less documented. In this study the Comparison for mechanical properties will be made between will be made between Conventional technique, Milled and 3D printed occlusal splints

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This introduction sets up a broad comparative study on occlusal splint fabrication techniques. Here's how this topic breaks down:
Topic Map
  1. Occlusal splints - fundamentals: definition, indications (TMD, bruxism), mechanism of action (deprogramming ICP, muscular/articular balance), types (stabilization/Michigan, anterior repositioning, soft vs hard)
  2. Occlusal forces & biomechanical demands: normal (107-156 N) vs parafunctional/bruxism forces (up to 794 N), implications for material selection
  3. Conventional fabrication: self-cure vs heat-cure acrylic resin, residual monomer issue, polymerization shrinkage, clinical drawbacks
  4. CAD/CAM Milling (subtractive): workflow, materials (pre-polymerized PMMA blocks), mechanical property advantages, evidence base
  5. 3D printing (additive manufacturing): photopolymer resins, printing technologies (SLA/DLP/FDM), mechanical property considerations, why literature is sparser
  6. Comparative mechanical properties: flexural strength, hardness, wear resistance, dimensional accuracy/fit, fracture resistance - conventional vs milled vs 3D-printed
  7. Clinical performance implications: which technique best withstands occlusal/parafunctional loads, durability, cost/time tradeoffs
A quick overview: occlusal splints are hard acrylic devices used to manage TMDs and bruxism by disengaging habitual occlusion and creating a new neuromuscular equilibrium. Historically they're made with self-cure or heat-cure PMMA, but these techniques suffer from residual monomer content and polymerization shrinkage that can compromise strength and fit over time. Digital dentistry has introduced two newer routes: milling, which subtracts material from industrially pre-polymerized, highly cross-linked PMMA blocks (generally denser and more homogeneous than hand-mixed acrylic), and 3D printing, which builds splints layer-by-layer from photopolymerizable resins (more variable properties depending on printer technology, layer orientation, and post-curing). Because splints must survive repeated heavy occlusal/parafunctional loading (up to ~794 N) without fracturing, deforming, or wearing excessively, comparing flexural strength, hardness, and fracture toughness across these three fabrication methods is clinically meaningful - milled splints are the most studied and generally show superior mechanical properties, while 3D-printed splints are newer and less consistently characterized in the literature.
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