Cutting and drilling guides manufactured using computer-aided design/computer-aided manufacturing (CAD/CAM) technologies have attracted increasing interest in orthognathic surgery, particularly in complex cases. The development of these guides requires virtual surgery planning and three-dimensional modelling before they can be printed in titanium, polyamide or resin. We report the use of a personalized titanium device to assist bilateral sagittal split osteotomy (BSSO) with or without genioplasty combined with individual implants for repositioning and fixation. This one-piece guide for both sides of the BSSO allows the initiation of cutting and drilling with less invasive drill placement and greater accuracy.

The titanium guide was manufactured using CAD/CAM technologies after conventional digital planning of BSSO. Intraoperatively, the guide was fitted on each side of the mandibular occlusal surface and screwed to predesigned drill holes. The guide facilitates the predrilling of screw holes and the initiation of cutting for buccal, lingual and external oblique ridge corticotomy using a piezosurgery device.

Based on our experience, we think that this guide is a promising new tool to assist BSSO. It helped limit the extent of tissue detachment required and provided the strength necessary for accurate bone cutting and drilling. It also allowed the accurate fixation of preformed plates to obtain occlusion as per virtual planning.