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3D printed plastics for beam modulation in proton therapy.

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Fused filament fabrication (FFF) and PolyJet™ (PJ) 3D printing methods were evaluated for proton therapy (PT) energy modulation. PolyJet™ demonstrated superior accuracy and material properties, closely matching poly(methyl methacrylate) for PT applications.

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Area of Science:

  • Medical Physics
  • Materials Science

Background:

  • Proton therapy (PT) utilizes energy modulation for precise dose delivery.
  • 3D printing offers potential for custom PT components, but material properties and accuracy require validation.

Purpose of the Study:

  • To assess the suitability of fused filament fabrication (FFF) and PolyJet™ (PJ) 3D printing for creating components used in clinical PT energy modulation.
  • To compare the printing precision, density, and stopping power of FFF and PJ printed materials against standard materials like poly(methyl methacrylate) (PMMA).

Main Methods:

  • Investigated FFF and PJ 3D printing techniques for PT energy modulation components.
  • Measured printing accuracy, void fraction, and mean stopping power for both methods.
  • Printed site-standard PT modulator wheels using FFF and PJ.
  • Compared measured depth-dose profiles of printed wheels with PMMA using a 74 MeV proton beam.

Main Results:

  • FFF exhibited 0.1 mm accuracy with a 13% void fraction, showing geometry-dependent stopping power.
  • PJ achieved 0.05 mm accuracy, with density and stopping power consistent with solid PMMA.
  • Both methods produced defects (~0.2 mm) at sharp edges.
  • Depth-dose profiles from FFF wheels showed poor agreement with PMMA; PJ wheels agreed within 1% of treatment dose, with a minor distal falloff discrepancy.

Conclusions:

  • PolyJet™ printing is a promising method for producing accurate components for proton therapy energy modulation, closely replicating PMMA properties.
  • Fused filament fabrication shows limitations in precision and material consistency for PT applications due to voids and geometric dependency.
  • Further optimization is needed to address printing defects in both methods for widespread clinical adoption in proton therapy.