Computer-aided design and rapid manufacture of an orbital prosthesis.

This clinical report presents a novel approach that integrates a new optical digitizing (scanning) technique, a three-dimensional ocular prostheses database, and the Selective Laser Sintering technique to achieve the computer-aided design and manufacture of an orbital prosthesis. An optical-structured light scanner was used to develop a color digital model of the unaffected orbital contour, which was copied and then mirrored to generate the orbital prosthesis contour data. The ocular prostheses database was applied to ascertain the size and position of the eyeball within the orbital prosthesis. Then, a Selective Laser Sintering machine directly manufactured the wax pattern of the definitive orbital prosthesis from the three-dimensional orbital data. This new approach is time and cost-effective and can be considered an alternative to traditional manual techniques of creating facial prostheses.