Purpose: To show the applications of Rapid Prototyping technique (RP)in the mandible reconstruction.

Methods: We treated 20 patients that were divided into 2 groups. Group A underwent by RP and the free vascularized fibular flap (FVFF), and Group B underwent by FVFF as control. The time of the surgery and the rate of the complications were compared between group A and B with two samples t -test, by using SPSS16.0 software package.

Results: There were significant differences between two groups, in terms of the time of the surgery and the rate of the complications. All the patients of group A were healed without any complications and vascular crisis. They had the symmetrical face and good occlusion. It took less time and had lower rate of the complications in group A. While one of group B occurred vascular crisis, and was healed with the right saving.

Conclusions: RP provides an advanced way to reconstruct the mandibular defects, and avoids the disadvantages that the surgeon spells the fibular during the traditional operations without references. It can not only save the surgery time, but also improve the accuracy and reduce the rate of the complications.