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This paper describes computer‐aided design (CAD) and rapid prototyping (RP) systems for the fabrication of maxillofacial implant.

Design methods for medical RP of custom‐fabricated are presented in this paper. Helical computed tomography (CT) data were used to create a three‐dimensional model of the patient skull. Based on these data, the individual shape of the implant was designed in CAD environment and fabricate by RP process. One patient with a large mandible defect underwent reconstruction with individual prefabricated implant resulting from initial surgical failure with hand contoured reconstruction plate.

Results shows that the custom made implant fit well the defect. Overall, excellent mandible symmetry and stability were achieved with the custom made implants. The patient was able to eat. There was no saliva drooling after the reconstruction. The operating time was reduced.

The methods described above suffer from the expensive cost of RP technique.

This method allows accurate fabrication of the implant. The advantages of using this technique are that the physical model of the implant is fitted on the skull model so that the surgeon can plan and rehearse the surgery in advance and a less invasive surgical procedure and less time‐consuming reconstructive and an adequate esthetic can result.

The method improves the reconstructive surgery and reduces the risk of a second intervention, and the psychological stress of the patient will be eliminated.

This paper aims to describe computer‐aided design and rapid prototyping (RP) systems for the preoperative planning and fabrication of custom‐made implant.

A patient with mandible defect underwent reconstruction using custom‐made implant. 3D models of the patient's skull are generated based on computed tomography image data. After evaluation of the 3D reconstructed image, it was identified that some bone fragment was moved due to the missing segment. During the implant design process, the correct position of the bone fragment was defined and the geometry of the custom‐made implant was generated based on mirror image technique and is fabricated by a RP machine. Surgical approach such as preoperative planning and simulation of surgical procedures was performed using the fabricated skull models and custom‐made implant.

Results show that the stereolithography model provided an accurate tool for preoperative, surgical simulation.

The methods described above suffer from the expensive cost of RP technique.

This method allows accurate fabrication of the implant. The advantages of using this technique are that the physical model of the implant is fitted on the skull model so that the surgeon can plan and rehearse the surgery in advance and a less invasive surgical procedure and less time‐consuming reconstructive and an adequate esthetic can result.

The method improves the reconstructive surgery and reduces the risk of a second intervention, and the psychological stress of the patient will be eliminated.