Development of Architected Materials for External Breast Prostheses

• Proposes a design concept utilizing 3D-printed architected materials to create breast prostheses that closely replicate the properties of natural tissue. • Creates design framework that combines analytical model, simulations, and experiments to replicate the density, thermal conductivity, and stiffness of breast tissue. • Improves thermal comfort and achieves accurate tissue-like density. • Demonstrates the potential of additive manufacturing to create lightweight, thermally comfortable, and anatomically customized prosthetics. Breast cancer remains the most prevalent cancer among women, with mastectomy often performed as a standard treatment or preventive measure. Post-surgery, breast prostheses are essential for restoring appearance, balance, and confidence. However, conventional silicone external prostheses often fall short in addressing key challenges such as comfort, weight, heat management, and personalization. This study presents a new design framework for External Breast Prostheses (EBPs) utilizing gyroid-based architected materials fabricated through additive manufacturing. By mimicking the density, thermal conductivity, and mechanical properties of natural breast tissue, the proposed design achieves advancements in realism and functionality. Tailored gyroid unit cell geometries enable precise control over weight distribution, thermal regulation, and stiffness, aligning with the properties of natural tissue. Guided by numerical simulations and validated through experimental testing, this approach produces a lightweight, breathable, and realistic prosthesis that can enhance comfort and functionality. This approach highlights the transformative potential of advanced imaging and 3D printing technologies in creating customizable, high-performance solutions to improve the quality of life for breast cancer patients.