Reconstructive surgery field is looking for sustainable alternatives on its procedures, specifically on affordable alternatives to manufacturing processes for medical devices. This paper outlines a design process to develop 3D printed medical devices for reconstructive surgery in a specific patient who had congenital, oncological or traumatic fracture cases in the face and/or skull. The implementation of the design process strategy was supported using endogenous capabilities and resources at Universidad Industrial de Santander, which could be applied in developing countries. So, this approach might offer solutions adapted to the South American population. For this reason, the research framework was a specific patient implant method, defined by modeling integration technologies, those supported by 3D virtual biomodels, computer-aided design, and rapid prototyping tools. A deep research has carried out with some surgeons within reconstructive surgery field, identifying needs and requirements for each case through an iterative process. Expected results of this paper were a workflow definition for 3D printed medical device development for a specific patient. Five cases were processed through the proposed workflow. From those cases, main identified outputs were related to devices such as implants, prosthesis surgical cutting guides, and pre-surgical planning to be performed. The proposed workflow showed strong viability implementation in future services among different academics and health facilities located in developing countries.