An instrumented intra-oral appliance that has been designed computationally to optimize the location and coupling of sensors to optimize data integrity while maximizing comfort for the wearer. The 3D anatomical geometry can be collected directly with an intra-oral scanner or indirectly through an impression and scan of a dental stone model. A generalized design can be created to fit a target audience by obtaining 3D anatomical geometries of the target populations and performing a statistical shape analysis. Once the generalized design of the electronics is created, a unique design can be generated for each individual by locating the electronics such that they collect the best quality data possible. The individual designs can also be generated that maximize comfort for the wearer by minimizing size and volume, avoiding areas that could be painful, and ensuring proper retention of the device. Although not required, the device could be 3D printed to convert the computational design directly to an appliance.