3D printed lightweight breast prostheses for a patient of breast size 38F who was unhappy with the heavy weight of their silicone prosthesis

• Bespoke breast prosthesis offers improved fit, contour matching, and reduced weight. • Patients with large prosthesis can experience comfort issues with standard silicone prosthesis. • A bespoke prosthesis was created from a scan of her residual breast and 3D printed. • Two 3D scans were taken, one of the residual breast and of the mastectomy site. • The 3d printed prosthesis is lightweight and is symmetrical with existing breast. Breast prostheses offer symmetry and femininity restoration for women post-mastectomy. They are fitted to an individual's bra size, but standard prostheses can be heavy and uncomfortable on the scar site. Custom-made breast prosthesis offers improved fit, contour matching, and reduced weight, which is beneficial to patients. We report a case of a specific patient with a large prosthesis who experienced significant comfort issues with her standard silicone prosthesis, and how a bespoke prosthesis was created from a scan of her residual contralateral breast and created using 3D printing such that it was lightweight. Two 3D scans were taken, one of the patient's residual contralateral breast while wearing a comfortable and well-fitting bra, and the other of the mastectomy site. The scans were processed using STL file editing software Meshmixer and Nomad Sculpt, and the residual breast profile was isolated and mirrored across the centerline of the patient's body. This profile was then aligned with the mastectomy surgery site scan and combined to create the anterior side of the prosthesis. A Vat Polymerisation (VP) 3D printing technology was used to produce the breast prosthesis, which was 3D printed on a FormLabs 3B+ using the FormLabs Flexible 80A material. The new 3d printed prosthesis design is lightweight and flexible and mirrors the existing breast to achieve anatomical symmetry. The bespoke prosthesis is 62 % lighter than the patient's previous silicone prosthesis. Additionally, the anterior of the prosthesis is a bespoke match of the mastectomy scar site, providing for a secure fit. The patient has worn her custom-made breast prosthesis for over one year up to the time of writing, and continues to do so. She describes the prosthesis as comfortable, lightweight, and secure in her bra. The use of 3D printing presents an opportunity to enhance the quality of breast prosthesis according to individual patient preferences.