Recent developments in additive manufacturing technique make it possible to build complex and customized products faster than with traditional methods. Reverse engineering (RE) and computer-aided design are crucial when creating sophisticated, patient-specific implants since they speed up the design process. In this study, computed tomography (CT) data in DICOM format was used to generate a 3D reconstructed model of the skull using the RE method. For implant design the mirror image technique was used. Prior to fabrication, the .stl file of the skull and implant was smoothen out and the mesh errors were removed using Meshmixer software. Fused deposition modelling-based 3D printer was used to fabricate the cranium and the implant using polylactic acid (PLA) and acrylonitrile styrene acrylate (ASA) materials, respectively. Using Ti-6AL-4V material under a 50 N load in a static condition, the design capability of the implant was evaluated using the finite element method (FEM). The FEM results demonstrate the feasibility of using an implant design for cranioplasty application. The prototype of skull and implant was effective in assessing the fractured part precisely. This 3D-printed prototype facilitates better surgical planning and expedites the fabrication of real metallic implants.