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Updated: Jun 19, 2025

Rapid and Low-cost Prototyping of Medical Devices Using 3D Printed Molds for Liquid Injection Molding

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Published on: June 27, 2014

A Simulation-Free Replacement Solution for Radiation Therapy Immobilization Devices Using Computer Numerical Control

Samuel Hellman¹, Laszlo Voros¹, Victoria Y Yu¹

¹Department of Medical Physics, Memorial Sloan Kettering Cancer Center, New York, New York.

Advances in Radiation Oncology

|July 25, 2024

Summary

This summary is machine-generated.

A new simulation-free method uses CNC milling of extruded polystyrene (XPS) foam to quickly and affordably replace lost or damaged radiation therapy (RT) immobilization devices, improving patient convenience and reducing costs.

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Area of Science:

Medical Physics
Biomedical Engineering
Radiation Oncology

Background:

Radiation therapy (RT) immobilization devices are crucial for accurate treatment delivery.
Loss or damage necessitates resimulation, leading to delays, increased radiation exposure, and costs.

Purpose of the Study:

To describe and evaluate a simulation-free method for fabricating replacement RT immobilization devices.
To assess the feasibility, cost-effectiveness, and accuracy of this novel approach.

Main Methods:

Utilized existing simulation scans as templates for computer numerical control (CNC) milling of extruded polystyrene (XPS) foam molds.
Evaluated XPS material properties (attenuation, bolusing) and established a clinical workflow.
Treated 12 patients and analyzed setup reproducibility using Dice Similarity Coefficient (DSC) and Mean Distance to Agreement (MDA).

Main Results:

XPS foam demonstrated favorable dosimetric properties compared to standard materials.
Replacement molds cost $242.17 and took 86.3 minutes of hands-on time, significantly faster and cheaper than resimulation.
Setup reproducibility showed high agreement (DSC avg. 0.966, MDA avg. 2.694 mm).

Conclusions:

CNC-milled XPS foam offers a rapid, cost-effective, and accurate alternative for replacing RT immobilization devices.
The method ensures satisfactory patient immobilization with minimal dosimetric impact.
This approach provides a viable solution for clinicians facing device replacement challenges.