BackgroundVirtual surgical planning (VSP) for composite microvascular free flaps has become standard of care for oncologic head and neck reconstruction. Controversy remains as to the use of three-dimensional (3D)-printed titanium patient specific implants (PSI) versus hand-bent stock reconstruction plates. Proponents of PSIs cite improved surgical accuracy, reduced operative times, and improved clinical outcomes. Detractors purport increased cost associated with PSIs and presumed equivalent accuracy with less expensive stock plates. PurposeThe study purpose was to measure and compare the 3D-volumetric accuracy of PSI versus stock reconstruction plates among subjects undergoing VSP-guided mandibular fibular free flap reconstruction. Study Design/Setting/SampleA retrospective cohort study of subjects undergoing VSP-guided fibular free flap reconstructions at Mayo Clinic between 2016-2023 was performed. Subjects were excluded for non-VSP guidance, midfacial reconstruction, non-fibular free flaps, and lack of requisite study variables. Predictor VariableThe primary predictor was the type of reconstruction plate utilized (PSI versus stock plate). Main Outcome VariableThe main outcome was volumetric surgical accuracy of the final reconstruction compared to the preoperative surgical plan by root mean square error (RMSE) calculation. Lower RMSE values indicated a higher surgical accuracy. CovariatesCovariates included age, sex, race, smoking status, ASA classification, Charlson Comorbidity Index, preoperative diagnosis, and number of fibular segments. AnalysisDifferences in surgical accuracy were assessed between pre- and post-operative segmented scans using volumetric overlays from which RMSE values were calculated. Univariate and multivariate modeling of plate type to RMSE calculation was performed. Statistical significance set to p<0.05. ResultsTotal of 130 subjects were identified, 105 PSI and 25 stock plates. Calculated mean RMSE in millimeters (mm) for stock plates was 1.46 (SD: 0.33) and 1.15 (SD: 0.36) for PSIs. Univariate modeling demonstrated a statistically significant difference in RMSE of 0.31 (95% CI: 0.16-0.47) (p<0.001) equating to a 21.2% (p<0.001) improved volumetric surgical accuracy for PSIs. The association of improved volumetric accuracy with PSIs maintained in all multivariate models controlling for confounding. Conclusion and RelevanceIn modern era VSP-guided head and neck fibular free flap reconstruction, patient-specific 3D-printed titanium implants confer a statistically significant improvement in volumetric surgical accuracy over stock reconstruction plates.