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The purpose of this paper is the production of mechanical meta-material samples by rapid prototyping (RP) and replica technique for patient-specific skin graft or cranial implant applications in tissue engineering.

Positive moulds (patterns) were produced by stereolithography-based RP. Impression moulding method was used for the production of silicone products (skin grafts). Alginate was used as a moulding material (negative mould). Room temperature vulcanising silicone was poured into the cavity of alginate mould and then products were produced. TiO₂ powder and carbon fibres were used as reinforcement. Meta-material structured polyurethane reinforced silicone composites were also produced. Liquid components (diisocyanate and polyol) were poured into the mould and then polyurethane was produced. Then, polyurethane was immersed in the liquid silicone.

It is found that non-destructive ultrasonic test is a fast and reliable method. Meta-material-based composites show dome-shaped tensile/synclastic surface properties which are important for the skin graft and cranial implants. Increasing the amounts of cross-linking agent and TiO₂ particles increased the hardness and elastic modulus. Carbon fibre addition enhanced the elastic modulus.

Although there are studies on the meta-materials, there is limited study on the RP of the meta-materials for patient-specific implants (skin grafts). Auxetic surface shows perfect fit to curved surface of the skull. Although there are studies on the silicone and polyurethane composites, there is limited study on the characterisation of mechanical properties by ultrasonic tests and strain gauge analysis.