3D Printed Cranial Immobilization with Adjustable Range Compensator

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Solution Overview

Problem

Conventional radiation therapy immobilization devices require multiple patient visits, involve external manufacturers, and are costly, with inefficiencies in beam delivery due to the need for multiple adjustments and shipping, especially when using FLASH RT which demands precise and rapid beam adjustments to minimize healthy tissue exposure.

Innovation Solution

A cranial immobilization device with a shell made of high Z material and a range compensator supported by scaffolding, allowing for precise adjustment and placement of material inserts to shape the radiation dose distribution, enabling quick adjustments for different beam geometries and minimizing healthy tissue exposure, facilitated by 3D printing for on-site production.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional immobilization devices are used with external manufacturers, then manufacturing precision can be achieved, but loss of time increases due to multiple patient visits and shipping

Engineering Contradiction:

Improveimmobilization device precisionVSAvoidpatient visit time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The treatment center fabricates immobilization devices using its own 3D printer rather than outsourcing to external manufacturers. The imaging device and treatment device are integrated in the same facility, allowing the treatment center to self-produce custom immobilization devices based on patient scans, eliminating the need for external manufacturing services and reducing patient visits.

Inventive Principle:

Principle #25Self-service

2Measurement precision

If range compensator adjustments are made manually for different beam geometries, then beam precision can be maintained, but productivity decreases due to time-consuming adjustments

Engineering Contradiction:

Improvebeam targeting precisionVSAvoidtreatment speed

Core Design Contradiction:

Measurement precisionVSProductivity

Solution Approach 1:

The range compensator is designed with movable, adjustable components that can be quickly repositioned for different beam geometries. The compensator includes multiple positioning locations and can be rapidly adjusted between different configurations without requiring time-consuming manual reshaping, enabling fast switching between treatment angles while maintaining precise beam targeting.

Inventive Principle:

Principle #15Dynamics

3Manufacturing precision

If multiple beams are used to treat irregular targets, then dose distribution can be optimized, but object-affected harmful factors increase due to healthy tissue exposure

Engineering Contradiction:

Improvedose distribution precisionVSAvoidhealthy tissue radiation exposure

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The immobilization device and range compensator are customized for each patient's specific anatomy and tumor location. The 3D imaging captures the unique geometry of the patient's head and target, allowing the immobilization device to be shaped specifically for that patient. The range compensator is similarly customized to account for varying tissue depths and beam paths, optimizing dose distribution for each patient's specific condition while minimizing exposure to healthy tissues.

Inventive Principle:

Principle #3Local quality

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This solution reduces the need for external manufacturers, minimizes patient visits, and enables efficient, precise radiation therapy by allowing for rapid adjustments and uniform dose delivery across targets, improving treatment efficiency and comfort while reducing costs and exposure to healthy tissues.

Implementation Method 1

The shell can be made of a high Z material to degrade the energy of a beam applied to the patient

Methodology Applied

Scientific EffectEnergy degradation through high Z material interaction: Compton Scattering

Implementation Method 2

The range compensator fine tunes the depth and range of the beam so that the Bragg peak is located within a target of the patient

Methodology Applied

Scientific EffectBeam energy absorption and range modulation: Photoelectric Effect

Data Source

PatentUS20230191154A1Material inserts for radiation therapy

Publication Date: 2023.06.22 VARIAN MEDICAL SYST PARTICLE THERAPY

AI summary

A system for treating a patient during radiation therapy is disclosed. The system includes a shell, a plurality of material inserts disposed in the shell, where each material insert of the plurality of material inserts respectively shapes a distribution of a dose delivered to the patient by a respective beam of a plurality of beams emitted from a nozzle of a radiation treatment system, and a scaffold component disposed in the shell that holds the plurality material inserts in place relative to the patient such that each material insert lies on a path of at least one of the beams.