Previously, we have found that the build-up dose from abutting narrow electron beams formed with unfocussed electron multi-leaf collimator (eMLC) steal leaves was higher than with the respective open field. To investigate more closely the effect of leaf material and shape on dose in the build-up region, straight, round (radius 1.5 cm) and leaf ends with a different front face angle of α (leaf front face pointing towards the beam axis at an angle of 90 − α) made of steel, brass and tungsten were modelled using the BEAMnrc code. Based on a treatment head simulation of a Varian 2100 C/D linac, depth–dose curves and profiles in water were calculated for narrow 6, 12 and 20 MeV eMLC beams (width 1.0 cm, length 10 cm) at source-to-surface distances (SSD) of 102 and 105 cm. The effects of leaf material and front face angle were evaluated based on electron fluence, angle and energy spectra. With a leaf front face angle of 15°, the dose in the build-up region of the 6 MeV field varied between 91 and 100%, while for straight and round leaf shapes the dose varied between 89 and 100%. The variation was between 94 and 100% for 12 and 20 MeV. For abutting narrow 6 MeV fields with total field size 5 × 10 cm2, the build-up doses at 5 mm depth for the face angle 15° and straight and round leaf shapes were 96% and 86% (SSD 102 cm) and 89% and 85% (SSD 105 cm). With higher energies, the effect of eMLC leaf shape on dose at 5 mm was slight (3–4% units with 12 MeV) and marginal with 20 MeV. The fluence, energy and angle spectra for total and leaf scattered electrons were practically the same for different leaf materials with 6 MeV. With high energies, the spectra for tungsten were more peaked due to lower leaf transmission. Compared with straight leaf ends, the face angle of 15° and round leaf ends led to a 1 mm (for 6 MeV) and between 1 and 5 mm (12 and 20 MeV at a SSD of 105 cm) decrease of therapeutic range and increase of the field size, respectively. However, profile flatness was better for abutting 6 MeV beams with round (2.5%) and face angle 15° leaves (3.0%) compared to straight leaf shape (5.2%). The eMLC leaves with a face angle of 15° resulted in a marked increase in the build-up dose for the single narrow eMLC beam and thus in the dose in the build-up region from matched abutting fields.
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