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Purpose

The purpose of this paper was to find a successful treatment modality for patients suffering from temporomandibular joint (TMJ) ankylosis who could not be treated through traditional surgeries.

Design/methodology/approach

This work integrated the unique capabilities of the imaging technique, the rapid prototyping (RP) technology and the advanced manufacturing technique to develop the customised TMJ implant. The patient specific TMJ implant was fabricated using the computed tomography scanned data and the fused deposition modeling of RP for the TMJ surgery.

Findings

This approach showed good results in fabrication of the TMJ implant. Postoperatively, the patient experienced normalcy in the jaw movements.

Practical implications

Advanced technologies helped to fabricate the customised TMJ implant. The advantage of this approach is that the physical RP model assisted in designing the final metallic implant. It also helped in the surgical planning and the rehearsals.

Originality/value

This case report illustrates the benefits of imaging/computer‐aided design/computer‐aided manufacturing/RP to develop the customised implant and serve those patients who could not be treated in the traditional way.

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