Osseous craniofacial defects are commonly seen problems after operative treatment of craniosynostoses. This case report describes a calvarial reconstruction by means of computer-aided fabrication of a customised implant. Three-dimensional imaging is followed by computer-aided design and fabrication of a medical grade PCL-TCP biodegradable scaffold using the rapid prototyping technology fused deposition modelling (CAD/CAM). After six months the implant was well integrated, no defect area could be palpated any more and a beginning bony consolidation could be detected via CT.