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In the present work advancement in replication techniques for a biomedical component having a real 3D shape has been introduced. A hip joint, made of ABS material, was fabricated as a master pattern (as one of a real 3D biomedical implant) by fused deposition modelling (FDM). After this mold was made by the deposition of primary, secondary and tertiary coatings with the addition of nylon fiber (1-2 cm in length of 1.5D) as per the Taguchi L9 control log of experimentation. This study outlines replication procedure of hip joint in detail from the master pattern to a final product with some investigation on dimensional accuracy. The results of study highlights that during shell production, fiber modified shells had a much reduced drain time. This gave a higher ceramic retention rate after dipping and led to a thicker coat compared to that produced without fiber addition.