To improve the maxillofacial surgery outcome, modern manufacturing methods such as rapid prototyping (RP), reverse engineering (RE) and medical imaging data have been utilised to manufacture custom-made prostheses after previous failed reconstructive surgery. After acquisition of data, an individual computer-based 3D model of the bony defect was generated and transferred into RE software to create the prosthesis CAD model. Then the physical model of the prosthesis was fabricated by RP technique. The precise fit of the prosthesis was evaluated using the prosthesis and skull models. The prosthesis was then directly used in investment casting such as “Quick Cast” pattern to produce the titanium model. In the clinical reports presented here, reconstructions of one patient with large mandible bone defects were performed using this method. The custom prostheses perfectly fit the defects during the operations, and surgery time was reduced. These cases showed that the prefabrication of a prosthesis using modern manufacturing technology is an effective method for maxillofacial defect reconstruction.