Introduction: This report detailed the application of a digital workflow in complex occlusal reconstruction, focusing specifically on temporomandibular joint disorder (TMD) patients. Case description: A 28-year-old female, who had been managed at TMD specialty clinic for the past year with occlusal splint stabilization, presented to the prosthodontic department for occlusal rehabilitation. Comprehensive clinical examination revealed a treatment plan comprising endodontic treatment, implant therapy, prosthetic treatment, and periodic TMD evaluations. After having comprehensively addressed all intraoral pathologies, we initiated prosthodontic rehabilitation. A dental virtual patient was established through integration of multisource digital datasets including the intraoral sacn (TRIOS 3; 3shape; Denmark), jaw motion tracer (JMA+; Zebris Medical GmbH; German), and facial scan (3D face app; Shanghai Jijia; China), enabling precision restorations design and fabrication digitally. Following provisional restorations delivery, iterative occlusal adjustments established an optimized functional occlusal relationship. Subsequent integration of intraoral scanning and digital jaw motion tracer captured the most stabilized occlusal relationship with associated kinematic parameters, enabling definitive prosthesis fabrication and application. Throughout the two-year follow-up period, all therapeutic outcomes remained clinically satisfactory with complete absence of TMD recurrence. Discussion: For patients with TMD, precision rehabilitation is imperative to prevent disease recurrence. Compared to conventional methods, the digital approach enhances restorative efficiency while ensuring kinematic-dynamic harmony between temporomandibular joint movements and occlusal relationships. Conclusion/clinical significance: Occlusal reconstruction with the aid of digital methods can achieve satisfactory results for patients. Digital methods merits wider application in occlusal reconstruction, especially in complex clinical cases.