Background: Computer aided planning of free vascularized fibula flap is introduced for treating cases with bone defects. Objective: The aim of the current study was to evaluate the effectiveness and benefits of planning and simulation in the outcome of free fibula flap (FFF). Patients and methods: A total of 30 cases were managed in Menoufia University Hospital, Plastic and Reconstructive Surgery Department, between March 2020 and May 2023. The participants in our study were 15 consecutive patients (Group 1) who had free fibula flap mandibular reconstruction utilizing CAD-CAM technology and 15 more patients (Group 2) had free fibular mandibular repair using standard methods. Results: In contrast to the conventional group (812 minutes), the CAD-CAM group's overall intraoperative duration was much less (662 minutes). In the CAD-CAM group, only 1 patient had postoperative malocclusion, compared to 6 individuals in the conventional group. Conclusion: The computer aided planning is effectively allowing the procedure to be performed with less time, effort, complications and hospitalization time, moreover increased accuracy, better functional and aesthetic outcome.