Additive manufacturing of external breast prosthesis: design, fabrication and mechanical characterization

Abstract

This work aimed to redesign a personalized prototype of an external breast prosthesis using additive manufacturing technology. The primary objective was to develop a prosthesis capable of closely simulating the deformation characteristics of a natural breast while adhering to the principles of Hooke’s law and being able to withstand the pressures exerted by typical bras. To achieve this, a detailed 3D scan of a volunteer’s breast was employed as the foundation for the prosthesis model. Multiple prototypes were crafted, each utilizing a gyroid structure with varying fill percentages, including 5%, 7.5%, 10%, and 25%. Comprehensive compression tests were conducted following ASTM D1621 standards. The results indicated that the 7.5% fill percentage prototype exhibited superior deformation properties under less applied pressure. Furthermore, extensive design evaluations were conducted to optimize 3D printing parameters and minimize the need for internal printed supports. This work underscores the potential of additive manufacturing as a promising technique for producing external breast prostheses that offer functional support and prioritize comfort and natural aesthetics.