This study evaluates the stress distribution in titanium and magnesium mini plates used for mandibular fracture fixation, focusing on the impact of plate thickness and fracture orientation. Using finite element analysis, we assessed the stress levels at three thicknesses (1.25 mm, 1.5 mm, and 2.0 mm) of mini plates across favorable and unfavorable fractures. For titanium plates, the maximum stress observed was 49.81 MPa at 1.25 mm thickness in vertical fractures, decreasing to 34.87 MPa at 1.5 mm but increasing to 38.36 MPa at 2.0 mm. In contrast, magnesium plates showed maximum stress of 37.94 MPa at 1.25 mm, with a notable decrease to 30.15 MPa at 1.5 mm, ultimately reducing to 26.53 MPa at 2.0 mm. Results indicate that magnesium plates maintain lower stress levels across thicknesses, which is particularly advantageous in favorable fractures, with stress levels of 30.65 MPa and 28.07 MPa at 1.25 mm and 1.5 mm, respectively. In unfavorable fractures, magnesium plates also exhibited lower stress than titanium plates, reinforcing their suitability for patients with lower bone density. These findings highlight the importance of selecting appropriate materials and thicknesses based on specific fracture characteristics. Magnesium plates may provide a more stable mechanical environment, whereas titanium plates are preferred in scenarios that require higher mechanical strength. This study offers critical insights for optimizing surgical outcomes in mandibular fracture treatments, suggesting further research into the long-term clinical implications of both materials.