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It is well known that medical imaging and visualization play important parts in traumatological orthopaedic surgery. Conventional radiological techniques including digital X-rays, computerized tomography (CT) and magnetic resonance imaging (MRI) have been widely used in clinic, but they have limitations. In order to achieve much deeper understandings and even better orthopaedic surgical interventions for complex fracture cases, eligible three-dimensional (3D) bone and joint simulations are desired. In this study, a CAD based 3D digital reconstruction system and a rapid prototyping (RP) technique were used to form 3D visualization and physical models of complex extremity fractures (CEF). Applications of the innovative biomedical simulation techniques and benefits of the 3D visualization and biomodeling in the highly difficult extremity fractures were elucidated.