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AbstractPurpose -The purpose of this paper is to describe a computer-aided design/manufacturing (CAD/CAM) system for fabricating facial prostheses. Design/methodology/approach -The CAD/CAM system can be used for fabricating custom-made facial prostheses with symmetrical or asymmetrical features. This system integrates non-contact structured light scanning, reverse engineering and rapid prototyping manufacturing technology. Fringe projection based on the combination of the phase-shift and grey-code methods is used for data collection. A robust approach is proposed to calculate the mid-plane of the human face without any knowledge of the centroid position or the principal axis in data processing. Findings -Results show that the proposed method increases the fabrication accuracy and reduces the operating time. Patients were satisfied with the rehabilitation results as the custom-made facial prostheses fitted them well. Practical implications -This study improves the fabrication accuracy of facial prostheses. Three-dimensional data of the facial surface of a patient needing a facial prosthesis were obtained with almost no harm to his body; after a series of robust processes, a precise and suitable aesthetic facial prosthesis was fabricated. Originality/value -This system has bright prospects for clinical application because of its advantages over other methods in terms of speed, accuracy, safety, cost, etc.
