C alvarial reconstruction following trauma, tumour excision or craniotomy is a common procedure performed by craniofacial surgeons and neurosurgeons. Alloplastic cranioplasty using materials such as titanium mesh, polymethyl methacrylate (PMMA) and polyether ether ketone, offers many advantages over autologous cranioplasty including unlimited availability, elimination of donor site morbidity, permanent shape and volume retention, and relative ease of manipulation during surgery (1). In current practice, there are two primary methods of alloplastic cranioplasty: manual intraoperative contouring of the alloplastic cranioplasty material to fit the skull defect in situ; or use of prefabricated, patient-specific implants.Simple skull defects are adequately reconstructed by manual intraoperative shaping of titanium mesh or molding of PMMA in situ. However, accurate restoration of normal skull shape by manual contouring is exceedingly difficult for large defects with complex surface geometry. Prefabricated patient-specific implants, designed using a patient's computed tomography (CT) data to precisely restore the missing anatomy, are increasing in popularity as a surgical solution for these more complex cranial defects. These implants reduce surgical complexity, decrease operative times, minimize exposure and risk of contamination, and have resulted in improved cosmesis and patient satisfaction (1,2).The fabrication of custom implants normally relies on preoperative processing of the patient's CT data, the computer-assisted design of a virtual implant model and subsequent manufacture of the implant. The implant is prefabricated well in advance of surgery for a stable, unalterable skull defect that must be clearly defined before the planned operative procedure. Herein lies the major disadvantage of prefabricated, patient-specific cranioplasty implants. An unanticipated intraoperative finding requiring modification of the defect, renders the implant useless. More importantly, in all surgical procedures in which the size of the defect is not known before surgery, prefabricated implants cannot be used. Patient-specific implants are, therefore, not available to patients undergoing ablative tumour surgery, trauma surgery, or any cranial vault reconstructions potentially requiring intraoperative resection or modification.The optimal method for alloplastic cranioplasty would enable costeffective creation of a patient-specific implant with the capacity for intraoperative modification. The present article describes a technique that uses a patient's CT scan data to create a custom forming tool (ie, mold) that enables intraoperative creation of a custom titanium mesh implant. These implants have the unique capacity for intraoperative modification in the event that the size of the defect is unknown preoperatively, or if alteration of an existing skull defect is required. Representative surgical cases will be presented, demonstrating the ability of this technique to achieve anatomical restoration of virtually any calvarial shape and...