Human bone tumors, severe trauma, and infection are the main causes of large bone defects. Currently, these defects are repaired using reconstruction plates that connect remaining bone, without any bone grafting. This study focuses on two aspects: the first, experimental testings using digital image correlation and secondly numerical testing studies in order to evaluate the influencing factors in the design of a custom prosthesis and maxillofacial applications. In this work, it is proposed to design and characterize a prototype mandibular prosthesis for hemimandibulectomy recovery class IVc to a patient with bone cancer. For the design and prototype, the physical and morphological characteristics of the patient as well as the strength properties of the used material are necessary. The mandibular prosthesis prototype design will be created based on the 3D reconstruction of the mandible of tomographic studies, which were obtained using the ScanIP software. Subsequently, the 3D models were exported to a CAD software in order to fix the necessary adaptations to the bone. The 3D models were printed in acrylonitrile butadiene styrene, and a digital image correlation was used in order to evaluate the residual stress and strain differences which can be observed in all the cases, also in the case of implants and the remaining healthy bone, caused by masticatory forces.