We present a unique case of mandibular reconstruction using virtual surgical planning (VSP) of a posttraumatic mandibular non-union defect for a patient with familial dysautonomia (FD), also known as Riley-Day Syndrome. In this case, the complexity related to perioperative and surgical challenges illustrates the utility of VSP and the importance of multi-disciplinary collaboration in jaw-free flap reconstructive surgery. We highlight our experience with the "Jaw-In-A-Day" approach in conjunction with tailored preoperative planning and perioperative care resulting in successful mandibular free flap reconstruction.