A workflow pipeline has been constructed and tested for rapid prototyping of outer ear replicas, incorporating 3D scanning, image post-processing, and 3D printing using various synthetic materials. Handheld and volumetric scanners, open-source software solutions, and the availability of 3D printers make time- and cost-effective procedures already possible. The demonstrated solutions may extend or replace expensive tissue engineering methods; thus, they can contribute to new business models and sustainability in facial reconstruction surgery. This allows not only for aesthetic improvement of the patients but also for the restoration of acoustic properties of the outer ears.