Objective To propose a personalized design, optimization and manufacturing method of three- dimensional (3D) printed implants for repairing large area of maxillary defect. Methods Based on the patient’s cone beam computer tomography (CBCT) and oral scan data information, the implant design was optimized at first. The structure and material selection of the implant were iteratively optimized by finite element analysis method . The force of the implant in oral cavity was simulated, the stress magnitude, conduction direction and distributions of the implant were obtained, and the implant structure was optimized accordingly. Finally, the maximum equivalent stress of the implant and the mandible, as well as the total displacement of titanium screws with the same configuration under three different materials, namely, titanium alloy, tantalum metal and polyetheretherketone (PEEK) were obtained, so as to determine printing material of the implant. Finally, the implant was printed using 3D printing technology, and facial remodeling and occlusal reconstruction were completed in clinic. Results Through iterative optimization of the structure, the best configuration of the implant was obtained, and the titanium alloy material was selected. The 3D printed implants were used in clinic to complete occlusal reconstruction. Conclusions The method described in this study has clinical feasibility and is suitable for different types of maxillary defect cases. The designed implant is accurate in size and has preferable mechanical properties. It can not only restores the patient’s maxillofacial appearance, but also meets the clinical needs of occlusal reconstruction after maxillofacial defect repair.