Objective: To analyze the effectiveness of personalized 3D-printed rehabilitation orthotics in the postoperative recovery of jaw fractures. Methods: Relevant data were collected from 42 patients with jaw fractures treated at our hospital between October 2017 and May 2020. Patients were randomly divided into a traditional group (n = 17) and a modified group (n = 25). The traditional group received standard rehabilitation methods, while the modified group used personalized 3D-printed rehabilitation orthotics combined with improved rehabilitation methods. The temporomandibular disability index (TDI), quality of life scores, postoperative recovery excellence rate, and mouth opening were compared between the two groups at different follow-up times (before rehabilitation, and at 1 week, 3 months, and 6 months post-surgery). Results: At 1 week, 3 months, and 6 months post-surgery, the TDI in both the traditional and modified groups was significantly lower than before rehabilitation, with statistically significant differences (P < 0.05). At 3 and 6 months post-surgery, the TDI in the modified group was lower than in the traditional group, with statistically significant differences (P < 0.05). At 3 and 6 months post-surgery, pain, appearance, activity, recreation, work, chewing, swallowing, speech, shoulder function, and total quality of life scores in both groups were higher than before rehabilitation, with the modified group showing significantly higher scores in pain, appearance, chewing, swallowing, and total quality of life (P < 0.05). Compared to before rehabilitation, mouth opening significantly improved in both groups at 3 and 6 months post-surgery, with the modified group showing significantly greater improvement (P < 0.05). Conclusion: Personalized 3D-printed rehabilitation orthotics are highly effective in the postoperative recovery of jaw fractures. They can improve patients’ quality of life after surgery, enhance the excellent rate of postoperative recovery, and increase mouth opening.
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