The possibility of developing customized 3D-printed silicone hydrogel bolus for post-mastectomy radiotherapy

3D printing technology is widely used for fabricating bolus in post-mastectomy radiotherapy. 3D printed boluses are usually made from hard materials like Polylactic Acid, which can’t adhere to patients’ skin perfectly in clinical practice because of the patients’ uneven surfaces of chest walls and large radiotherapy area. In this work, the feasibility of 3D printing soft self-adhesion boluses using water tissue equivalent silicone hydrogel material in post-mastectomy radiotherapy was studied, and intensity modulated radiotherapy plans were designed to study the performance of the water tissue equivalent silicone hydrogel bolus by comparing to the results of using virtual boluses with the relative electron density of 1.09 in radiotherapy. The comparison demonstrated that water tissue equivalent silicone hydrogel boluses have better adhesive property than boluses made from hard materials. The average air gap volume between the water tissue equivalent silicone hydrogel bolus and patients’ skin is 9.5 cc. The average degree of adhesion and average maximuum air cavity dimension are 3.7% and 4.3 mm, respectively. The dose distribution of the virtual bolus and the water tissue equivalent silicone hydrogel bolus are roughly the same in Dose Volume Histogram.