Purpose　-　To　present　a　custom　design　and　fabrication　method　for　a　novel　hemi-knee　joint　substitute　composed　of　titanium　alloy　and　porous　bioceramics　based　on　rapid　prototyping　(RP)　and　rapid　tooling　(RT)　techniques.　Design/methodology/approach　-　The　three-dimensional　(3D)　freeform　model　of　a　femur　bone　was　reconstructed　based　on　computerized　tomography　images　via　reverse　engineering　and　the　3D　reconstruction　accuracy　was　evaluated.　The　negative　image　of　artificial　bone　was　designed　with　interconnected　microstructures　(250-300　mu　m).　The　epoxy　resin　mould　of　a　hemi-knee　joint　and　the　negative　pattern　of　an　artificial　bone　were　fabricated　on　Stereolithography　apparatus.　Based　on　these　moulds,　a　titanium-alloy　hemi-knee　joint　and　a　porous-bioceramic　artificial　bone　were　created　by　quick　casting　and　powder　sintering　(known　as　RT)　techniques,　respectively.　After　assembling,　a　composite　hemi-knee　joint　substitute　was　obtained.　Findings　-　The　3D　reconstructed　freeform　model　of　the　femur　bone　conformed　to　the　original　anatomy　within　a　maximum　deviation　0.206　mm.　The　sintered　artificial　bone　had　interconnected　micropores　(250　mu　m)　and　microchannels　(300　mu　m).　After　implanting　in　vivo,　the　composite　hemi-knee　joint　substitute　matched　well　with　the　surrounding　tissues　and　bones　with　sufficient　mechanical　strength.　Research　limitations/implications　-　Further　in-vivo　research　is　needed　to　provide　the　evidence　for　tissue　growth　into　the　ceramic　structures　and　long-term　viability　and　stability　of　the　implant.　Originality/value　-　This　method　enhances　the　versatility　of　using　RP　in　the　fabrication　of　tissue-engineered　substitutes,　especially　when　individual　matching　is　considered.　Although　this　paper　took　a　customized　hemi-knee　joint　substitute　as　an　example,　it　is　capable　of　fabricating　other　artificial　substitutes　with　a　variety　of　biomaterials.