Background
External breast prostheses (EBPs) play a vital role in post-mastectomy care, with approximately 80 percent of U.S. mastectomy patients relying on them to restore symmetry, improve self-image, and enhance quality of life. Despite their widespread use, conventional silicone-based prostheses often fail to meet patients' comfort and personalization needs. Many users report shoulder pain, general fatigue, and overheating, all of which stem from poor thermal regulation and inadequate material properties. Additionally, current solutions offer limited customization for individual size, shape, and body fit, resulting in prostheses that do not replicate the biomechanical feel of natural breast tissue.
Technology overview
This technology presents a custom-fitted external breast prosthesis created through 3D scanning and additive manufacturing. Using 3D photographs of the chest wall, a CAD model is generated to ensure a precise anatomical match. The prosthesis is printed using a soft, biocompatible polymer embedded with a gyroid triply periodic minimal surface lattice. This lattice is engineered to achieve a density and compressive modulus that closely match natural breast and adipose tissue. Lobed regions of the prosthesis replicate glandular tissue properties, while the porous gyroid structure enhances isotropic mechanical support and significantly improves thermal conductivity.
The result is a lightweight, breathable prosthesis with a 21.5 percent increase in thermal efficiency and reduced weight compared to traditional solid silicone devices. This patient-specific approach offers a natural look and feel while reducing physical discomfort and thermal stress.
Benefits
- Custom-fit design based on 3D patient imaging
- Improved thermal regulation for enhanced comfort
- Lightweight architecture mimics natural breast density and softness
- Lobed regions simulate denser glandular tissue for realism
- Significantly reduces fatigue, shoulder pain, and overheating
Applications
- Post-mastectomy care
- Personalized external breast prostheses
- Reconstructive and cosmetic prosthetics
- Adaptive wearables in medical device design
Opportunity
- Fulfills unmet need for comfortable, patient-specific breast prostheses
- Differentiated by thermal efficiency and anatomically accurate customization
- Strong potential in consumer health and medical device markets
- Available for exclusive licensing
