A method of manufacturing a surgical cut validation tool is discussed. A digital bone representation representing a bone is received including a virtual bone outer surface. At least one cutting plane is positioned intersecting the virtual bone outer surface. A digital tool representation representing the tool is created, including a virtual planar surface corresponding to each cutting plane and a virtual tool outer surface with a virtual border surface portion. The virtual border surface portion extends from a junction between the virtual tool outer surface and each virtual planar surface. At least part of the virtual border surface portion is defined from a corresponding portion of the virtual bone outer surface such as to represent a corresponding portion of the bone outer surface. The tool body is manufactured using the digital tool representation. A tool and a method of validating a cut in a bone are also provided.
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