Objectives: This investigation sought to develop a mapping apparatus for use in the assessment of both tooth and restoration wear. Methods: A computer controlled mapping device, capable of scanning a suitably prepared electroconductive tooth replica by means of an electrical feedback mechanism, was constructed and its accuracy assessed by measuring the thicknesses of four engineers' slip gauges 12 times each. The reproducibility of three potential methods of rendering a die stone replica electroconductive was also investigated. Finally, tooth replicas were surface profiled and compared empirically with the originals using a commercial surface mapping program. Results: The overall mean accuracy of the mean thicknesses of the slip gauges was 4.4 (2.8) μm. Surface deposition of either nickel spray or gold leaf, upon a ready formed replica, did not give a reproducible thickness. Precoating silicone impressions with nickel spray prior to replica production overcame this problem. On an empirical basis the instrument yielded accurate digital terrain models of tooth replicas. Conclusions: A surface mapping device has been developed which is both accurate and reproducible. A satisfactory electroconductive surface may be produced upon a tooth replica by precoating a silicone impression with nickel spray before casting the replica. The technique should prove invaluable for monitoring both tooth and restoration wear but further work is necessary to examine how such an approach will perform clinically.