Purpose: Making impressions for maxillectomy patients is an essential but difficult task.This study developed a novel method to fabricate individual trays by computer-aided design(CAD)and rapid prototyping(RP)to simplify the process and enhance patient safety.Methods: Five unilateral maxillectomy patients were recruited for this study.Based on the 3D surface reconstruction of the target area,an individual tray was manufactured by CAD/RP.With a conventional custom tray as control,two final impressions were made using the different types of tray for each patient.The trays were sectioned,and in each section the thickness of the material was measured.Statistics were used to examine the difference of the impression thickness.Afterwards,all casts were then optically 3D scanned and compared digitally to evaluate the feasibility of this method.