Abstract—The objective of this research was to design and manufacture an implant for Augmentation Rhinoplasty, an additive plastic surgery of nose, to suit the face morphology of patients of the Indian subcontinent and to reduce the cost substantially by incorporating innovative design and manufacturing practices, thus overcoming the twin problems of deficiencies in design of existing implants and the high cost of around $150-$200 which puts them out of the reach of the needy. This research involves the customized design of nasal implant, design and manufacturing of die and setting up a manufacturing process for the implant. Design of implant involved customization of geometrical parameters to suit Indian subcontinental face morphology, solid modeling in Computer Aided Drawing (CAD) software and selection of a suitable implant grade material that fulfills the norms of biocompatibility for long term implantation. The design of die included solid modeling and selection of appropriate material. The solid modelling of the implant and the die was done using Solid Edge software. An appropriate grade of biocompatible Liquid Silicone Rubber (LSR) was selected to achieve required mechanical properties. Die casting process was selected for manufacturing the implant. Die was manufactured by Computer Numerically Controlled (CNC) machining followed by finishing operations to ensure mirror finish. Process parameters for the implant manufacturing were established after several experimental trials and the process was standardized. As a result, implant having desired design features and mechanical properties with no manufacturing defects was obtained. Manufacturing cost of the implant was reduced substantially to $20 apiece. The established standards of manufacturing process and materials in this research can be extended for making implants for other body parts like chin, calf and ear which will benefit trauma victims and those with congenital defects.