A method for designing a personalized medical device includes receiving a template design of a medical device. An image including a patient anatomical geometry is acquired. The template design is combined with the image including the patient anatomical geometry to create a custom medical device design. A region of interest encompassing the sharp concave edge is automatically identified within the custom medical device design using one or more seed points received from a user. Surface smoothing of the custom medical device design is performed within the region of interest to bolster a thickness of the custom medical device design. A 3D-printable model is obtained from the surface smoothed custom medical device design.