Craniofacial prosthesis are important medical solutions used to correct facial and cranial deformities, repair post-traumatic injuries, and serve aesthetic purposes. Prosthesis around the eye region play a crucial role in restoring visual functions and achieving facial symmetry. Conventionally, these prosthesis are often applied surgically using premanufactured standard models. However, in recent years, additive manufacturing technologies, notably 3D printers, have revolutionized this field. In recent years, computed tomography (CT) imaging techniques have played a significant role in designing personalized prostheses which are used in cases of orbital bone fractures or deformation. These techniques utilize data to analyze the patient’s orbital structure in detail and design a customized orbital reconstruction prosthesis based on that information. CT images are used to create a three-dimensional model of the patient’s face structure. This model visualizes the shape, dimensions, and other anatomical details of the facial bones. In this study, the processing and analysis of these images are done using Materialise Mimics and a computer-aided design (CAD) software Materialise 3-Matic. The designed prosthesis manufactured using a selective laser melting (SLM) device with 20 µm layer thickness using Titanium—6 Aluminum—4 Vanadium (Ti-6Al-4V) material which is proven to be biocompatible in the literature and medical applications. The size range of Ti-6Al-4V grade 23 powders used in our study is 15–45 µm and they have a spherical morphology. Personalized orbital reconstruction prosthesis, which was specially designed for the persons specific bone structure was produced using this method. To reduce the surface roughness, the produced prothesis was polished as a post-process.