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According to the University of Illinois Urbana-Champaign, a Carle Illinois College of Medicine (CI MED) team is using 3D scanning and printing technology to help breast cancer patients following a mastectomy – developing a process to create affordable, custom-fit breast prostheses in the physician’s office, bypassing the wait time and high cost of existing products.
“Some patients go without because they lack insurance coverage, can’t afford the out-of-pocket expense, or are simply unaware of their options,” said Dr. Victor Stams, Clinical Sciences Professor and Carle Health plastic surgeon at CI MED.
Stams is collaborating with CI MED student Rand Kittani on a process to produce low-cost, 3D printed prostheses, created at the point of care. “By offering an affordable and immediate alternative to traditional breast reconstruction surgeries, this initiative directly addresses the financial and social barriers associated with social determinants of health,” said Kittani.
For patients who don’t undergo breast reconstruction following a mastectomy, prostheses are commonly used to replicate the form of a breast under clothing. Prostheses can range in price from a little over a hundred dollars to thousands for custom-made options. The CI MED team aims to cut those costs to between $50 and $200, depending on the material. They’re also designing a process that can be completed in the physician’s office, eliminating lengthy production and wait times.
“Beyond cost and convenience, what excites me most is the opportunity to give patients a sense of dignity and control during a vulnerable time,” said Stams.
The idea of a 3D printed prosthesis was inspired by the work of anatomist Julien Montenero, CEO of REALETEE in Nice, France, who specializes in realistic, custom-fit breast prostheses created by capturing 3D imaging of a patient’s anatomy.
Kittani’s team is adapting that concept using 3D scanners and 3D printers that are readily available on the market. Before the patient undergoes a mastectomy, the care team would use 3D scanners to capture images of the patient’s healthy breast tissue. The scanned images would provide a digital pattern for a 3D printer to follow in creating a prosthesis that matches the patient’s unique anatomy. “The customization aspect of 3D printing also allows for a better aesthetic match, which can have a meaningful impact on body image and recovery,” said Stams.
Prostheses are typically made of silicone gel or other soft material. The more realistic, comfortable, and custom-fit the prosthesis, the higher the price. The CI MED team is prototyping their process with different materials, ranging from plastic and thermoplastic polyurethane (TPU), through to bioprinting materials, to determine the material that balances fit, comfort, and affordability.
Preliminary research from the team suggests future development potential by integrating advanced MRI software to achieve greater realism in prosthetic designs.
