We present an approach that combines Computer Tomography (CT), reverse engineering (RE) and rapid prototyping (RP) for individual implant production in maxillofacial surgery. 3D acquisition of the patient’s skull is performed, after acquisition of data; an individual computer-based 3D model of the bony defect is generated. These data are transferred into RE software to create the implant using a computer-aided design (CAD) model, which is directed into the RP machine for the production of the physical model. The implant is 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 mandible bone defects were performed using this method. The custom prostheses perfectly fit the defects during the operations, and surgery time was reduced.