3D-Printed Radiation Therapy Mask Lattice for Lower Surface Dose

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Solution Overview

Problem

Current patient immobilization devices for radiation therapy, such as thermoplastic masks, suffer from manual fabrication issues leading to inaccuracies, patient anxiety, and inefficiency, while existing 3D printing methods like FDM have limitations in reliability and material properties.

Innovation Solution

The use of multi-jet fusion (MJF) 3D printing to create mechanical metamaterial-based immobilization devices with a thin conformal shell and rigid lattice structure, which are customizable and reduce surface dose through optimized material thickness and geometry.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If manually fabricated thermoplastic masks are used for patient immobilization, then patient immobilization is achieved, but manufacturing precision and reliability are compromised due to manual fabrication limitations

Engineering Contradiction:

Improvemask fabrication accuracyVSAvoidmanual fabrication complexity

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent replaces manual mechanical fabrication processes with automated 3D printing technology. The immobilization device is manufactured using digital models and automated additive manufacturing, eliminating the need for manual heating, molding, and shaping of thermoplastic materials. This substitution ensures consistent manufacturing precision while reducing fabrication complexity and time.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of operation

If conventional thermoplastic immobilization devices are used, then patient immobilization is provided, but patient anxiety increases due to the mask fabrication and application process

Engineering Contradiction:

Improvepatient comfortVSAvoidpatient anxiety

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The patent implements preliminary customization of the immobilization device by creating a digital 3D model of the patient's anatomy before fabrication. This allows the device to be precisely tailored to the patient's unique features in advance, ensuring optimal fit and comfort from the first application. The preliminary digital planning eliminates the need for repeated adjustments and reduces patient anxiety by providing a predictable, comfortable experience.

Inventive Principle:

Principle #10Preliminary action

3Strength

If solid or mesh-based immobilization devices are used, then structural rigidity is achieved, but surface dose to the patient increases due to material thickness

Engineering Contradiction:

Improvedevice rigidityVSAvoidsurface dose

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent employs a lattice structure with controlled porosity instead of solid or mesh-based designs. The lattice geometry provides structural rigidity through its three-dimensional framework while the porous spaces reduce the effective material thickness and density along the radiation beam path. This porous architecture achieves the dual goal of maintaining device strength while minimizing surface dose to the patient.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The patent utilizes a composite structure combining a conformal shell with an integrated lattice framework. This composite design integrates both the conformal fit of a shell and the rigid support of a lattice structure, while the lattice's open architecture reduces material density. The composite approach optimizes the balance between mechanical rigidity and radiation transmission properties.

Inventive Principle:

Principle #40Composite materials

4Productivity

If traditional thermoplastic mask fabrication is used, then immobilization devices are produced, but productivity is reduced due to time-consuming heating, forming, and cooling processes

Engineering Contradiction:

Improvefabrication efficiencyVSAvoidfabrication time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The patent replaces the thermal processing mechanism (heating, forming, cooling) with automated 3D printing technology. The additive manufacturing process builds the immobilization device layer by layer from digital models without requiring thermal softening or prolonged cooling periods. This substitution dramatically reduces fabrication time while maintaining manufacturing precision and device quality.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS12551174B2Immobilization devices for radiation therapy

Publication Date: 2026.02.17 ADAPTIIV MEDICAL TECH INC

AI summary

Methods and devices are provided for fabricating and employing patient immobilization devices during radiation treatment procedures. Immobilization devices are provided that include a thin conformal shell configured to conform to an anatomical region of a patient that is to be exposed to radiation during a radiation treatment procedure, with a rigid lattice structure extending outwardly, in an external, beam-facing direction, from the conformal shell. The rigid lattice structure confers structural rigidity to the device, and the thin cellular regions mitigate the impact of the device on a surface dose delivered to the patient or subject. The present mechanical-metamaterial-based immobilization devices incorporate structural features that confer advantageous mechanical properties and radiation transmissive properties when compared with conventional solid or mesh-based immobilization devices used in radiation therapy.