Computer-assisted technique for the design and manufacture of realistic facial prostheses.

We describe a technique for the design and fabrication of realistic facial prostheses using three-dimensional optical imaging and computer-aided design and manufacturing (CAD/CAM). A three-dimensional dataset of the facial surface of a patient who needed a facial prosthesis was obtained using a sensing system, and the three-dimensional image of the face was reconstructed. A decreased and thinned virtual prosthesis was designed based on the facial image and converted into a rapid prototyping wax prosthesis using a selective laser sintering technique. The rapid prototyping wax prosthesis was then dipped into melted base-plate wax which generated a layer of wax on the internal and external surfaces to record its size and thickness. The modified prosthesis was evaluated and refined, and processed to generate a realistic silicone prosthesis. Three-dimensional data acquisition using the sensing system and computer-assisted design and manufacture of the prosthesis allows us to see a whole face without damaging the soft tissues or causing discomfort to the patient or exposure to radiation. The final prosthesis was of satisfactory size, shape, and cosmetic appearance, matched the malformed area, and suited the patient's requirements.