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The purpose of this study was to measure the performance of a new design of occlusal sensor, the high definition (HD) sensor, and directly compare this sensor to the previous design. This new HD sensor design has increased active recording area by 33%, and decreased inactive recording area by 50% as compared to the previous design (G3). This was accomplished by determining the force reproduction variability for repeated occlusal closures on the same sensor for a sampling of sensors from both designs. Thirty (30) G3 and 30 HD sensors were consistently positioned and loaded 24 times between articulated epoxy casts by a Pneumatic Occlusal Force Simulator. Their force reproduction consistency was measured as an electronic voltage drop across six occlusal contacts that were consistently located on all sensors. The force variability of the two sensor designs was determined by comparing the consistency of the voltage drops across the six occlusal contacts. An analysis of variance was employed to determine the variability of force reproduction over multiple closures across six occlusal contact regions. For five of the six contacts, the G3 sensor mean variances, were significantly larger (p<0.05) than those of the HD sensor. The within sensor variability of the HD sensor was significantly less than that of the G3 sensor. Within the limitations of this study, the HD sensor exhibited less variable force reproduction than the G3 sensor for at least 20 in-laboratory loading cycles. [ABSTRACT FROM AUTHOR]