BACKGROUNDS: Dentofacial deformities have many negative consequences in the form and function of head and neck region.This includes breathing, swallowing, speech and temporomandibular disorders.It is estimated that in about 19% of orthodontic patients, orthognathic surgery is required along with the orthodontic procedure.The introduction of Computer-aided design/ Computer-aided manufacture (CAD/CAM) technology in orthognathic surgery planning has facilitated the procedure and allowed for more predicted results. AIM OF THE STUDY:The aim of the present study was to propose a new design of the intermediate stent that relates the mobilized maxilla to a fixed anatomical landmark in the skull which would allow for more accurate positioning of the maxilla during orthognathic surgery. MATERIALS AND METHODS:This study was conducted on sixteen patients who required Le Fort I osteotomy procedure.Eight of them (group A) were treated via a conventional stent while the other eight patients (group B) via a CAD/CAM bone-borne stent.Postoperative patient evaluation was performed by comparing the predicted maxillary position to the resultant position postoperatively.This was done via 3D reconstruction Computerized Tomography (CT) scans.RESULTS: Sixteen patients were recruited for the study (n=16), 5 males and 11 females, and were randomly allocated into two groups.Age ranged from 16 to 42 years with a mean of 24.31 ± 7.49.No statistically significant difference was found in the operation time using Independent samples t-test (p<0.05).Pain evaluated by Visual Analogue Scale (VAS) was also found statistically insignificant between both groups using Independent samples t-test and Mann-Whitney U test (p<0.05).Error of superimposition was found to be statistically significant between control group (0.317±0.22) and study group (0.870±0.23) using independent samples t-test (p<0.05). CONCLUSION:The new intermediate splint design needs further modifications in order to better reproduce the planned maxillary position.