Abstract: In order to improve the individual matching of free fibula flap for mandible defect reconstruction， a custommade titanium plate design and manufacture were presented. The visualization and CAD were adopted to design the repair model with biomimetic shape by CT data. A finite element model of the mandible was created. The stress of the mandible before and after repair was compared with each other. Rapid prototyping was employed to build the resin mold， which can save the surgery time and improve the success rate. The mandible finite element analysis results show that the mandible stress concentration area was broadly distributed in mandible ankle protrusion area， mandibular angle，and the mandible repair. With increase of the loading force， stress increased significantly， especially in mandible ankle protrusion area and the mandible repair. The maximum stress appeared at the junction of the mandible and fibula. The high stress generalization of the repaired mandible was checked. Areas of stress concentration decreased significantly.

Key words: rapid prototyping, computer aided design(CAD), mandible reconstruction, customized design, finite element analysis