Designing accurate cranial implants of specific patient is a time consumption procedure for designing and manufacturing, hence, in the present work a fully and fast procedure for design and manufacturing a cranial implant have been done. Based on the biomedical engineering data the damaged zone has been detected as boundary intersection, adopted a special algorithm for surface reconstruction, rather than repairing the damaged members/zone based on additive manufacturing technology. Fixation parts and porosity have been designed to fix the implant with the skull, and decrease the overall weight of the designed implant, respectively. The difference between defective skull and the designed cranial implant have been achieved based on the image processing technique. The obtained difference value was ranged ±1.861984 mm, where the overall dimension of the studied skull was (205.7, 149.0, 154.9)mm, and the dimension of the designed cranial implant was (139, 131.1, 38.8)mm.