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Background To evaluate and establish a digital workflow for the custom designing and 3D printing of mouth opening tongue-depressing (MOTD) stents for patients receiving radiotherapy for head and neck cancer. Methods We retrospectively identified 3 patients who received radiation therapy (RT) for primary head and neck cancers with MOTD stents. We compared two methods for obtaining the digital impressions of patients’ teeth. The first method involved segmentation from computed tomography (CT) scans, as previously established by our group, and the second method used 3D scanning of the patients’ articulated stone models that were made during the conventional stent fabrication process. Three independent observers repeated the process to obtain digital impressions which provided data to design customized MOTD stents. For each method, we evaluated the time efficiency, dice similarity coefficient (DSC) for reproducibility, and the 3D printed stents’ accuracy. For the 3D scanning method, we evaluated the registration process using manual and automatic approaches. Results For all patients, the 3D scanning method demonstrated a significant advantage over the CT scanning method in terms of time efficiency with over 60% reduction in time consumed ( p < 0.0001) and reproducibility with significantly higher DSC ( p < 0.001). The printed stents were tested over the articulated dental stone models, and the trueness of fit and accuracy of dental anatomy was found to be significantly better for MOTD stents made using the 3D scanning method. The automated registration showed higher accuracy with errors < 0.001 mm compared to manual registration. Conclusions We developed an efficient workflow for custom designing and 3D-printing MOTD radiation stents. This workflow represents a considerable improvement over the CT-derived segmentation method. The application of this rapid and efficient digital workflow into radiation oncology practices can expand the use of these toxicity sparing devices to practices that do not currently have the support to make them. Electronic supplementary material The online version of this article (10.1186/s13014-019-1357-2) contains supplementary material, which is available to authorized users.

1. A defect of the middle of one tibial crest is described in young healthy ballet dancers. 2. The clinical and radiological characteristics have been studied in four cases, and the histological appearances in two. 3. The defect is concluded to be an incomplete fatigue fracture—a fatigue infraction. 4. A fifth, uncertain, case has been added tentatively, as presenting a possible serious complication, namely acute fracture from muscle action. 5. The diagnosis, treatment and prognosis are mentioned, with emphasis on the importance of adequate clinical and radiological examination in cases of obscure mid-tibial pain, tenderness or swelling.