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While computerized tomography (CT) and magnetic resonance imaging (MRI) technologies are highly commendable for their applications and usage, sometimes cases involving facial anatomy restoration may not necessarily require these highly sophisticated technologies. A suitable replacement that is also non‐contact and allows fast image capture is the laser digitizer surface scanner. This scanner takes only seconds to capture an image of the patient’s sound or healthy facial anatomy. By using the captured image data, it is possible, with the help of a surface data modeller rapid prototyping (RP) machine and vacuum casting machine, to manufacture the prosthesis for implant. Presents a novel approach for facial prosthesis fabrication through a case study of a prosthetic ear model using an integrated manufacturing system comprising the laser surface digitizer, surface data modeller, rapid prototyping system and vacuum casting system.