Rapid manufacturing of patient‐specific shielding masks, using RP in parallel with metal spraying

Abstract

Purpose -The purpose of the present work is to develop a methodology to manufacture patient-specific models (lead masks) to be used as protective shields during cancer treatment, using 3D photography, rapid prototyping (RP) and metal spraying. It is also intended to reduce the trauma experienced by the patient, by removing any physical contact as with conventional methods, and also to reduce the manufacturing lead time. Design/methodology/approach -Patient-specific data are collected using 3D photography. The data are converted to.STL files, and then prepared for building with an LS 380 in nylon polyamide. Next, the sculpted model is used as the mould in a newly patented metal-spraying device, spraying liquid metal on to the sculpted surface. Findings -Intricate body geometries can be reproduced to effectively create metal shields, to be used in radiography applications. The models created fit the patients more accurately than through conventional methods, reducing the trauma experienced by the patient, and in a reduced time-frame, at similar costs to conventional methods. The new process and its materials management are less of a an environmental risk than conventional methods. Research limitations/implications -Access to 3D photography apparatus will be necessary, as well as to RP or CNC equipment. Using this approach, files can be transferred to a central manufacturing facility, i.e. hospitals or treatment units do not need their own facilities. Added implications are the design of jigs and fixtures, which will ensure accuracy in reuse. Practical implications -Metal shields can be created with ease and great accuracy using RP machines. It takes less time without inflated costs. Models are more accurately and easy to use, with less trauma experienced by the patient during the manufacturing phase. Originality/value -Novel applications, combined with a new process. The research expands the fast-growing field of medical applications of RP technologies. Its practical application will benefit patients on a daily basis.

Three‐dimensional surface imaging for clinical trials: Improved precision and reproducibility in circumference measurements of thighs and abdomens

“…3D surface imaging technology is already utilized in computed-aided design and manufacturing to precisely measure the human body for garment manufacturing [1], and for manufacturing of custom-fitting equipment [2]. In dentistry, intra-oral 3D photography is widely used to create precise 3D models for dental implants and restorations [3].…”

Additive manufacture of custom radiation dosimetry phantoms: An automated method compatible with commercial polymer 3D printers

“…Radiation dose changes were then reported at 1 mm and 5 mm for materials manufactured by SLA (material: VisiJet SL Clear; manufacturer: 3D systems), polymer jetting (material: Vero White Plus; manufacturer: Stratysys), SLS (material: glass-filled polyamide PA3200GF, manufacturer: EOS). This work has some commonality with the patient-specific shielding masks developed by de Beer et al [63], whereby SLS (material: nylon polyamide) is used to generate a shell that is then used as a formwork for the deposition of radiation shielding material. In both cases, the AM shells are directly used clinically.…”

Customised design and manufacture of protective face masks combining a practitioner-friendly modelling approach and low-cost devices for digitising and additive manufacturing

“…Although this work only considered protective masks for nose fractures, the proposed methodology can be extended to other specific face regions that need to be treated. This is the case, for instance, of shielding masks for cancer treatment (Deon J. de Beer et al 2005) and hypertrophic scars as a result of burns (Powell et al 1985). These face masks could be also designed following the proposed methodology since the scanning process and the printing process would not require any changes.…”

“…In addition to this traditional technique, new technologies have been applied to minimise the abovementioned issues and satisfy patients' needs regarding a proper adjustment of the face mask (Deon J. de Beer et al 2005;Sanghera et al 2001). These technologies involve three dimensional scanners to capture facial features, Computer Aided Design (CAD) applications to model the mask and Additive Manufacturing (AM) to build the mask layer upon layer from the 3D data model.…”

“…The physical prototype can be later post-processed for particular applications with conventional existing techniques, such as metal spraying for patientspecific face masks necessary for radiography applications in cancer treatment (Deon J. de Beer et al 2005). Another alternative is to directly manufacture the virtual face using any available AM technology and use that face as mould later in the vacuum former to create the mask (Bibb et al 2004).…”