CAD-CAM generated ear cast by means of a laser scanner and rapid prototyping machine.

Sculpting a wax ear cast for use when making a definitive prosthesis for a patient who has had auricle ablative surgery, is challenging. It requires a skilled anaplastologist along with complex instrumentation able to perform facial laser scans and reproduce anatomic details. The aim of this article is to present a technique to create a cast by laser scanning a stone cast of the existing ear. A 3D laser scanner develops an integrated 3D digital image of the unaffected ear, which is copied and then mirrored. A rapid prototyping machine collects the necessary data to manufacture the definitive resin ear. This procedure is time and cost effective only if the technology is free of charge.