Snoring and obstructive sleep apnea (OSA) are disorders caused by atony of the upper airway dilator muscles leading to airway narrowing during sleep and affect approximately 47% of the population. Mandibular advancement devices (MADs) are widely recognized as an effective therapeutic option, consistently associated with higher patient satisfaction and accepted as a primary treatment alternative . However, information on digital workflows to produce MAD with computer-aided design and computer-aided manufacturing (CAD-CAM) technology using a virtual articulator is lacking. The purpose of this report is to present a technique to design and mill MADs from intraoral scans using a user-friendly software of an integrated CAD-CAM system with virtual articulator.

This case outlines a fully digital workflow developed to address key challenges in full-arch, implant-supported restorations. At the heart of this approach is Scanform (Short for scannable anatomic former), an innovative modular component created by Bilimplant (Bilimplant, Proimtech, Turkey). Scanform functions as both a healing abutment and a scan body, while also allowing for targeted soft tissue management and direct connection to Ti-base abutments. Additionally, a horizontal scanning cap can be fabricated and attached to the Ti-base either chairside or in the laboratory, potentially enhancing the accuracy of the digital impression. This ultimately improves clinical accuracy and streamlines the workflow. Following successful implant osseointegration, digital impressions were taken with Scanform components attached to the implants. These components stayed in place throughout the process, preserving the emergence profile and providing a foundation for fabricating a polymethylmethacrylate (PMMA) splint. This splint was used both to register the intermaxillary relationship and to verify the passive fit. It was mounted onto Ti-base abutments secured to the Scanform units and scanned using an intraoral scanner. The resulting digital data was used to design and produce monolithic zirconia restorations, which were then delivered to the patient with confirmed passive fit and proper occlusion. By eliminating the need to remove components during the impression and bite registration stages, this technique not only ensures accurate capture of emergence profiles and occlusal relationships but also enhances predictability, saves time, and significantly improves patient comfort. These advantages seem to result in a more practical and efficient solution for complex full-arch restorations.