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Supercritical CO2 (SCCO2) technology was used to eliminate the cells, fat and non-collagenous materials while preserving a native collagen scaffold as a biomedical device for bone defects. We used porcine matrix bones with 3D CAD/CAM carving to reconstruct a personalized, wide range and complex-shaped bone. In oral cancer patients upto 30–50% of need mandibulectomy and autologous fibula reconstruction. Autograft is the gold standard preference due to its histocompatibility; but, it needs extra surgery. Allograft and xenograft are substitutes but are vulnerable to immune response. At present, no personalized bone xenografts are accessible in the market for large fascial bone defects. In addition, a large-sized complex shape bone graft is not possible to be manufactured directly from the raw material. We forestall that patients can reestablish their native facial appearance after reconstruction surgery. We effectively established 3D CAD/CAM carved bone matrices, followed by SCCO2 decellularization of those large-sized bones. A lock-and-key puzzle design was employed to fulfil a wide range of large and complex-shaped maxillofacial defects. To conclude, the 3D CAD/CAMcarved bone matrices with lock and key puzzle Lego design were completely decellularized by SCCO2 extraction technology with intact natural collagen scaffold. In addition, the processed bone matrices were tested to show excellent cytocompatibility and mechanical stiffness. Thus, we can overcome the limitation of large size and complex shapes of xenograft availability. In addition, the 3D CAD/CAM carving process can provide personalized tailor-designed decellularized bone grafts for the native appearance for maxillofacial reconstruction surgery for oral cancer patients and trauma patients.
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