The development of rapid prototyping has evolved from crude milled models to laser polymerized stereolithographic models of excellent accuracy. The technology was advanced further with the recent introduction of fused deposition modelling and a three-dimensional ink-jet printing technique in stereo-model fabrication. The concept of using a three-dimensional model in planning the operation has amazed maxillofacial surgeons since its first application in grafting a skull defect in 1995. It was followed by many bright ideas for applications in the field of facial reconstructive surgery. Stereo-models may assist in diagnosis of facial fractures, joint ankylosis and even impacted teeth. The surgery can be simulated prior the operation of complex craniofacial syndromes, facial asymmetry and distraction osteogenesis. The stereo-model can be used for preparation of reconstructive plate or joint prostheses. It is of enormous value for educational teaching and as a patient information tool when obtaining the consent for surgery.