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Background Plastic bronchitis, also known as bronchial cast syndrome, is a rare but serious complication predominantly seen in children with congenital heart disease, particularly following Fontan-type surgeries. This disorder is characterized by the development of cohesive bronchial casts that may result in life-threatening obstruction of the airways. Methods We present a case series of three pediatric patients with complex congenital heart disease who developed plastic bronchitis after Fontan-style palliative surgery. We detail the clinical presentation, diagnostic workup, management, and outcomes of these patients. Results All three patients presented with acute respiratory symptoms and expectoration of bronchial casts. Each patient had previously undergone multiple prior cardiac surgeries, culminating in a Fontan-type procedure. Management of such patients focuses on symptomatic relief, supportive care, and, in some cases, bronchoscopy cast removal. Variable clinical courses and outcomes highlight the challenges in the diagnosis and management of this condition. Conclusion Plastic bronchitis in children with congenital heart disease necessitates a high clinical suspicion and a multidisciplinary approach for prompt intervention. Further research is required to improve outcomes in this vulnerable population.