Current 3D scanning and printing technologies offer not only state-of-the-art developments in the field of medical imaging and bio-engineering, but also cost and time effective solutions for surgical reconstruction procedures. Besides tissue engineering, where living cells are used, bio-compatible polymers or synthetic resin can be applied. The combination of 3D handheld scanning devices or volumetric imaging, (open-source) image processing packages, and 3D printers form a complete workflow chain that is capable of effective rapid prototyping of outer ear replicas. This paper reviews current possibilities and latest use cases for 3D-scanning, data processing and printing of outer ear replicas with a focus on low-cost solutions for rehabilitation engineering.

The combination of current technical possibilities of handheld 3D scanning devices, 3D data analysis and interaction, and novel 3D bioprinting technologies has opened the way to develop workflows and scenarios for the generation of personalized human prosthesis. Specifically, using the human ear as one example to develop a cost-effective chain of methods and tools, the above mentioned combined and interacting technologies can be used to understand and demonstrate the possibilities for rapid bio prototyping. Production workflows for personalized soft-material bio-prosthesis gain significance in reconstructive and plastic surgery. This paper introduces a workflow concept, presents a list of appropriate and accessible state-of-the-art handheld scanners, followed by an image processing solution based on the MeshLab application and printing first prototypes.