Computer-aided design and manufacturing technology in oral and maxillofacial reconstruction: a narrative review

Background and Objective: Computer-aided design and manufacturing (CAD-CAM) has transformed oral and maxillofacial surgery over the past few decades, offering patient-specific solutions for complex reconstructive needs. As a component of computer-assisted surgery (CAS), these technologies have improved surgical precision, efficiency, and outcomes. However, existing literature often evaluates virtual planning, manufacturing techniques, or biomaterials in isolation, without addressing how these elements interact within clinical workflows. This narrative review provides an overview of CAD-CAM materials, techniques, applications, outlines their historical evolution, and evaluates their relevance in contemporary maxillofacial surgery.

Methods: A literature search of studies published in English from 1995 to 2025 was performed. Relevant case reports, case series, cohort studies, and related reviews were examined to assess the use of CAD-CAM in virtual surgical planning (VSP), surgical guide development, and fabrication of patient-specific implants (PSIs). Particular attention was given to innovations in materials and additive manufacturing (AM) platforms, as well as the clinical benefits incorporating these technologies into surgical planning and reconstruction.

Key Content and Findings: CAD-CAM has demonstrated substantial value in maxillofacial surgery by improving accuracy, reducing operative time, and enhancing functional and aesthetic results. Advances in digital imaging and software enable detailed virtual planning, facilitating the production of surgical guides and biocompatible implants tailored to individual anatomy. Current applications include surgical templates, complex osseous reconstruction, and prosthetic design. Materials such as titanium, hydroxyapatite, and emerging polymers have supported successful outcomes in maxillary and mandibular reconstruction. Although much of the literature consists of small case series and non-randomized studies, growing evidence indicates that CAD-CAM contributes to lower complication rates, improved postoperative recovery, and higher predictability.

Conclusions: With parallel advancements in biomaterials and AM, CAD-CAM has become integral to contemporary oral and maxillofacial surgery. The materials and workflows described—including digitally guided osteotomies and PSIs—demonstrate improvements in precision, efficiency, and reconstructive accuracy. While some applications remain in early development, current evidence supports the clinical utility of CAD-CAM in achieving reliable outcomes. Continued progress in material science, digital tools, and manufacturing technology is expected to further expand its capabilities and reinforce its role as a standard component of future maxillofacial reconstruction.