Porous non-biodegradable polyethylene implants for treatment microtia have suboptimal material properties. Additive manufacturing opens unique opportunities for rational design and fabrication of patient specific biocompatible auricular implant with optimal material properties maintainable after implantation. The patient specific porous polyurethane auricular implant have been designed using laser scanner, finite element analysis, CAD software and fabricated using fused deposition modeling. The material properties of human cadaveric auricular cartilage and fabricated implants have been tested using three points flexure method. The biocompatibility and maintainability of fabricated auricular implant size and geometry have been texted in nude rats. The patient specific porous polyurethane auricular implants have been fabricated using fused deposition modeling. The optimal material properties comparable with native cadaveric human auricular cartilage have been achieved using rational design approach based on finite element analysis. The original shape and geometry of implant have been maintained up to 3 months after implantation with optimal level of biocompatibility. The patient-specific biocompatible porous polyurethane auricular implant with optimal material properties sustainable after implantation could be fabricated using fused deposition modeling. The hydrid approach with simultaneous deposition of hydrogel filaments containing chondrocytes between polyurethane filaments will enable bioprinting of patient specific hybrid tissue engineered auricular implant with optimal and maintainable material properties.