The appropriate application of computer-aided design and manufacture techniques in silicone facial prosthetics

Three-dimensional Computer Tomography (CT) data from a recent scan was used to obtain facial anatomy from a patient requiring an ocular prosthesis. The CT data was imported into the computer aided design (CAD) package, FreeForm® that was used to digitally design the prosthesis pattern using sculpting and shaping tools. The digital prosthesis pattern was then manufactured using a ThermoJet® rapid prototyping machine, printing in a wax material suitable for integration with traditional prosthesis Grafting techniques. Handcrafting and traditional laboratory techniques were then used to ensure the pattern fitted the patient and to integrate additional features before the mould was created. The final prosthesis was completed in silicone and successfully fitted to the patient with a pleasing aesthetic result.