3D printing is a form of additive manufacturing in which a thermoplastic filament is heated and sequentially layered to generate a 3D solid object. The precise specifications of the printer allows for the rapid production of sophisticated and customised models to a tolerance of <0.2mm. Through the use of computer aided design (CAD), it is also possible to print models based on a variety of input file formats, including images collected from radiological imaging. 3D printed model generation is already well-established by maxillofacial surgeons in fields such as orthognathic surgery, dental implantology and complex facial reconstruction, but this has not translated to widespread use by plastic surgeons. The simplest application of 3D printing technology in facial trauma the generation of a bony facial bone biomodel to enable the pre-bending of plates in complex panfacial trauma, allowing for optimal plate contouring without being hindered by soft tissues, difficult access or distorted bony landmarks intraoperatively. The model can be generated through exportation of the radiology DICOM imaging and 3D reconstruction to produce a high-resolution template model. This technology can also be applied to complex free flap reconstruction of the face such as free fibula flap for mandible reconstruction. The facial CT data is combined with digital images of facial soft tissue to generate a composite model that produces a jaw template that can be projected onto a CT of the donor fibula. A customised ideal osteotomy pattern is generated based on the patient’s particular anatomy and a bespoke cutting guide is generated, producing a much higher fidelity reconstruction for the patient.