A method of producing an orthopedic implant including the steps of building a flat open model of at least a portion of an implant. The flat open model may be built using a selective laser sinter process. The flat open model preferably includes at least one groove along either a first surface or a second surface of the model. Next a force may be applied to the flat open model at predetermined locations to thereby cause the model to bend and assume a shape similar to a desired result. The now bent model may be resurfaced by either applying additional material such that the bent flat open model assumes the shape of a desired implant or the bent open model may be snap fit to an additional element.