Orthognathic model surgery is a classical technique used to simulate orthognathic surgical cases. However, a detailed analysis of this technique demonstrates that theoretical errors and inaccuracies can occur in routine practice. 2D and 3D cephalometric analysis is the first source of inaccuracies. Then, during the occlusal plane transfer from the patient to the semi-adjustable dental articulator, errors can occur by inaccurate manipulation of the facial bow. Simulating the operation on the plaster cast is difficult due to the lack of a real link between the cephalometric analysis and the model surgery. Rotation and translation movements of the plaster casts are insufficiently controlled during the model surgery stage. Finally, the splint, which transfers the final relative position of maxilla to the mandible, summates all of the errors of the previous stages.