A Free, Open-Source Toolkit to Produce 3D Bolus in the Clinic

Abstract

Tissue-equivalent, tissue-approximating and tissue-replacing bolus materials have been in use for decades in radiotherapy. Most frequently these materials are applied to a patient's skin to bring the highest dose region towards the surface of the skin-which is the location of the target. These materials can be applied at the time of simulation and included in a planning CT scan, or can be added during the planning process and first physically applied at the time of treatment. One of the most widely adopted materials for bolus has been sheets of a commercially available proprietary synthetic gel, which is uniform in thickness, and has some ability to match the curvature of the patient's body. Recently investigators have worked to create boluses using 3D printing technology, including several commercially available offerings. We hypothesized that we could create a bespoke, 3D bolus solution, using a series of open-source and free software products. For an anthropomorphic phantom, a radiation treatment plan representative of skin cancer treatment was designed, this included a superficial target. The DICOM CT and structure set were imported into 3D Slicer, which is a free, open-source software for visualization, processing, segmentation, and registration. Using 3D Slicer, the bolus structure was saved as an STL file. Meshmixer, a free software for working with triangle meshes, was used to complete a mold design, and the mold parts were then printed using a rigid filament on a 3D printer. The mold parts were glued together, and small spring clamps were used secure the walls to the shells to ensure mold integrity. The mold was then filled with a thinned and degassed silicone. After appropriate curing, demolding was completed by removing the clamps and separating the walls. After QA, the bolus was applied to the anthropomorphic phantom and CTs were taken to compare a commercial sheet bolus with the in-house 3D printed product. The bolus made via the in-house 3D printing process fit even complicated patient geometries well, and had both an obvious visual/goodness of fit advantage over the commercial sheet bolus and a nuanced dosimetric improvement as the air gaps present in the commercial sheet bolus were not desirable nor reproducible. The overall in-house workflow was efficient, and clinically reasonable (an estimated time of 72 hours was presented to the physician team, but in testing less than 24 hours was needed from export to delivery of the finished product). In this work we explored whether motivated groups and departments could produce dosimetrically accurate and clinically reasonable custom boluses for patients undergoing radiotherapy to a superficial area of the body, using a test case on an anthropomorphic phantom. We found that this was absolutely achievable and could be implemented with no funds spent on software or licenses. Provided that a 3D printer, filament and silicone are available, any thoughtful practice can join the bespoke-bolus-club.