With the integration of digital workflows in dentistry, digital models can now be articulated inter-occlusally through different digital techniques. The Cadent iTero intraoral scanner records the maxillomandibular relationship via a buccal scan taken in maximum intercuspation. This in-vitro research evaluated the occlusal accuracy obtained from traditional stone cast articulation compared with that of digitally articulated quadrant-milled models. Thirty pairs of stone casts made from full-arch polyvinyl siloxane impressions (Group A) and thirty polyurethane quadrant models milled from digital impressions (Group B) were used. The full-arch casts were manually articulated and mounted on semi-adjustable articulators, while the digital models were pre-mounted by the milling center using buccal scan data. Bite registrations for both groups were acquired using a T-scan sensor. The occlusal data collected from both groups were compared to a master model to assess reproducibility. A statistically significant variance in contact surface area was detected on tooth #11 of the digitally articulated models relative to the master. Force distribution analysis also revealed a greater load tendency on the anterior #11 tooth in digital models. Within the study’s limitations, digitally articulated quadrant systems may lose occlusal accuracy, particularly in anterior restorations. Attention to potential error sources in the digital workflow is essential to optimize restorative precision and efficiency.
