3D Printed Radiation Modulator Manufacturing via Digital Feedback
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Solution Overview
Problem
Conventional methods for manufacturing radiation beam intensity modulators are inefficient, prone to errors, and require significant space and resources, making them unsuitable for precise and rapid production, especially in medical settings.
Innovation Solution
A method and apparatus utilizing a 3D printer to manufacture radiation beam intensity modulators by obtaining dose modulation information and design conditions, adjusting the structure according to actual manufacturing and treatment conditions, and printing the modulator, which allows for precise and rapid production without the need for large spaces or noisy cutting processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional cutting methods using milling are used to manufacture radiation beam intensity modulators, then manufacturing precision can be achieved, but the process generates severe noise, contaminated coolant water, requires wide space, and is time-consuming
Solution Approach 1:
The patent replaces conventional mechanical cutting methods (milling) with a 3D printing system that uses digital modeling and additive manufacturing. The treatment planning system generates a 3D model of the modulator based on patient-specific anatomy and tumor geometry, which is then manufactured using a 3D printer. This substitution eliminates mechanical cutting processes, thereby removing the associated noise, coolant contamination, and space requirements while significantly reducing manufacturing time.
Solution Approach 2:
The invention changes the manufacturing approach from subtractive (cutting) to additive (3D printing) processes. By transforming the modulator design into a digital 3D model with precise geometric parameters derived from medical imaging data, the system enables direct manufacturing of patient-specific modulators. This parameter-based digital manufacturing approach maintains high precision while improving productivity and eliminating environmental contaminants.
2Reliability
If radiation collimators are used to shield radiation and obtain desired intensity modulated radiation, then radiation intensity can be controlled, but errors may occur due to collimator malfunction and scattered dose calculation difficulties
Solution Approach 1:
The patent extracts the radiation shielding function from conventional collimators and implements it through patient-specific 3D-printed modulators designed with precise geometric features. The modulator structure is directly optimized based on treatment planning parameters, eliminating the need for complex collimator mechanisms. This extraction of the shielding function to a simplified, custom-designed component reduces malfunction risks and improves reliability.
Solution Approach 2:
The invention performs preliminary design and optimization of the modulator structure using treatment planning software before manufacturing. The 3D model is created with precise geometric parameters that account for radiation scattering and attenuation characteristics. By pre-calculating and incorporating scattered dose considerations into the design phase, the system eliminates the need for complex real-time collimator adjustments and reduces information loss about scattered dose distribution.
3Productivity
If 3D printing is used to manufacture radiation beam intensity modulators, then manufacturing speed and precision are improved, but new manufacturing processes and materials must be validated
Solution Approach 1:
The patent implements a feedback mechanism where the 3D-printed modulator is quality-checked against the original 3D digital model after manufacturing. The system compares the physical modulator's geometric parameters with the designed parameters to ensure they match within acceptable tolerances. This feedback loop validates the manufacturing process and ensures reliability by confirming that the printed modulator accurately reproduces the treatment-planned geometry.
Solution Approach 2:
The invention creates an accurate physical copy of the digital 3D modulator model through 3D printing. The printing process reproduces the treatment-planned geometric features with high fidelity, creating a carbon copy of the virtual design. This copying approach ensures that the manufactured modulator matches the treatment plan specifications, validating the new manufacturing process while maintaining reliability.
4Ease of manufacture
If conventional manufacturing facilities with cutting equipment are used, then modulators can be manufactured, but large space is required and environmental contamination occurs
Solution Approach 1:
The patent replaces mechanical cutting facilities with a 3D printing system that uses digital modeling and additive manufacturing. This substitution eliminates the need for noisy cutting equipment and coolant systems, thereby removing the harmful environmental factors while maintaining ease of manufacture. The 3D printer operates in a controlled environment without generating noise or contamination.
Solution Approach 2:
The invention converts the manufacturing process from a harmful mechanical cutting operation to a beneficial additive process. Instead of removing material and generating waste (coolant water and noise), the 3D printing process builds the modulator layer by layer from powder or resin material, minimizing waste and eliminating harmful byproducts. The process transforms a potentially harmful manufacturing method into an environmentally friendly one.
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
The method enables precise and rapid manufacturing of radiation beam intensity modulators, reducing errors and environmental impact, allowing for more efficient radiotherapy with reduced treatment duration and improved precision, especially for moving organs.
Implementation Method 1
manufacturing the radiation beam intensity modulator based on the adjusted radiation beam intensity modulator structure
Data Source
AI summary
Provided are a method and apparatus for manufacturing a radiation beam intensity modulator. The method includes: obtaining dose modulation information expressed as a density matrix or three-dimensional (3D) structure information provided from a radiotherapy treatment planning system; obtaining design condition information of a radiation beam intensity modulator provided from the radiotherapy treatment planning system; generating a radiation beam intensity modulator structure based on the design condition information of the radiation beam intensity modulator and the dose modulation information expressed as the density matrix or the 3D structure information; adjusting the radiation beam intensity modulator structure by comparing at least one of an actual manufacturing condition and a treatment condition with the design condition information of the radiation beam intensity modulator; and manufacturing the radiation beam intensity modulator based on the radiation beam intensity modulator structure that is adjusted.