A research team at Carle Illinois College of Medicine (CI MED) is working on a process for the patient-specific production of breast prostheses using 3D printing technology. The aim is to provide women who have undergone a mastectomy with affordable and quickly available care directly in the doctor’s surgery. The project is a response to existing gaps in care, such as high costs, long waiting times or a lack of insurance cover.
Plastic surgeon Dr. Victor Stams and medical student Rand Kittani are developing a digital process chain in which 3D scans of healthy breast tissue are taken before the operation. Based on this scan data, a precisely fitting prosthesis can later be additively manufactured. The process is based on the concept of French anatomist Julien Montenero, but is implemented using commercially available scanners and printers. It should be possible to produce prostheses for around 50 to 200 US dollars – significantly cheaper than conventional custom-made products, which cost several hundred to thousand dollars.
“Some patients go without because they lack insurance coverage, can’t afford the out-of-pocket expense, or are simply unaware of their options,” said CI MED Clinical Sciences Professor and Carle Health plastic surgeon Dr. Victor Stams.
“By offering an affordable and immediate alternative to traditional breast reconstruction surgeries, this initiative directly addresses the financial and social barriers associated with social determinants of health,” Kittani said.
Technically, the team is testing various materials, including thermoplastic polyurethane (TPU) and biocompatible plastics, in order to achieve a balance between wearing comfort, realistic feel and cost. In the long term, the use of bioprinting and the integration of MRI data to improve anatomical accuracy are also being discussed.
“Beyond cost and convenience, what excites me most is the opportunity to give patients a sense of dignity and control during a vulnerable time,” Stams said.
“The customization aspect of 3D printing also allows for a better aesthetic match, which can have a meaningful impact on body image and recovery,” Stams explained.
The development was presented at the Surgeons and Engineers Symposium of the American College of Surgeons in March 2025.
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