In this paper, a novel method for reconstructing and fabricating a missing ear is presented based on rapid prototyping (RP) and the FreeForm modelling system. Using the method, the image of the normal ear is extracted, mirrored, and positioned onto the image of the deformed side of the face precisely, and the undersurface of the ear prosthesis can match the remnant tissue of deformed side perfectly without making a wax ear. In the clinic, six ear prostheses have been produced and applied successfully. The results suggest that high accuracy has been achieved in shape, size, and protrusion of the ear prostheses, which indicates that the application of RP techniques in conjunction with the FreeForm modelling system is a suitable approach for fabricating ear prosthesis.
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