Background Non-melanoma skin cancer (NMSC) is the most common cancer in Australia. The nose is a common site for NMSC, likely facilitated by the protrusion allowing greater sun exposure than the rest of the face. The trilaminar nasal reconstruction with a forehead flap described by Burget and Menick has become a ubiquitous choice for many reconstructive surgeons for reconstruction of full-thickness ala defects. Method A prospective, observational cadaveric study to assess the feasibility of developing a novel reconstructive technique following the principles of Menick’s trilaminar reconstruction, with the goal of achieving better symmetry, aesthetics and functional outcomes. The primary objective is to develop a 3D printed biodegradable scaffold that would be patient-matched to the contralateral ala to use as the middle, structural lamella in the second stage of the Menick reconstruction procedure as a substitute for cartilage or bone graft. The secondary objective is to examine the workflow of creating a patient-matched scaffold for a clinical procedure. Results Simulated trilaminar nasal reconstruction with a forehead flap was performed on 3 cadavers. Digital photography taken post-procedure demonstrated excellent aesthetic outcomes, as illustrated by clinical photography. The full study was completed within 24 hours, highlighting the streamlined process in developing a patient-matched scaffold for reconstruction. Conclusion A patient-matched custom 3D printed scaffold in a trilaminar reconstruction of a hemirhinectomy defect can achieve adequate or even superior symmetry and aesthetics compared to autologous tissue. It also has the potential to completely eliminate donor site morbidity, with superior function and form.