Methodology for design and additive manufacturing of radiotherapy bolus using 3D scanning: a low-cost alternative

Radiotherapy involves applying radiation doses to tumor cells and healthy tissue. To protect healthy tissue, an accessory called a bolus is used. Traditional boluses face issues such as limited adaptability and inconsistencies in radiodensity. This study proposes a low-cost process that uses 3D scans and additive manufacturing (AM) to design and produce custom boluses. The method uses a 3D scanner as an alternative to standard medical image acquisition, processes the images with CAD and mesh optimization, and then manufactures the pieces through additive manufacturing using polylactic acid (PLA) as the printing material. By optimizing the fill percentage, radiodensity was controlled, resulting in boluses that achieved a 65% cost reduction in material and an 81% savings in imaging compared to the traditional method.