<p>One of the main challenges of the integration of clear aligner therapy (CAT) in orthognathic surgery workflows is resuming postoperative treatment due to limited mouth opening of the patient in the early postoperative period. We present a single-case technical feasibility of a new workflow that eliminates the delay until the patient is able to open the mouth properly to perform an intraoral scan. A 20-year-old patient with Angle Class III malocclusion, anterior open bite, mandibular asymmetry and maxillary transverse deficiency underwent bimaxillary surgery with maxillary segmentation after presurgical CAT. Following confirmation of final occlusion and prior to extubation, the surgical splint was temporarily removed and maxillary and mandibular intraoral scans, including occlusal contacts, were obtained intraoperatively in 4 min using a standard protocol. The final surgical splint was repositioned and secured to maintain transverse stability. Scan files were uploaded the same day; aligners were delivered 2 weeks later. The splint was removed and postoperative CAT commenced. Treatment concluded uneventfully at six months with stable occlusion and satisfactory transverse dimension. Intraoperative full-arch scanning was feasible and enabled same-day digital file transfer for postoperative aligner manufacture, allowing aligner delivery at 2 weeks and initiation of postoperative CAT without complications. This approach removes the conventional 2- to 4-week delay to intraoral data acquisition and may facilitate earlier orthodontic activation. In segmented cases, earlier aligner availability may support transverse stabilization and reduce reliance on occlusal splints, with potential improvements in patient comfort. These findings represent a technical feasibility demonstration; prospective studies are required to confirm effects on treatment duration and long-term stability.</p>