Use of 3D-printers to create Intensity-Modulated Radiotherapy Compensator Blocks

Intensity-Modulated Radiotherapy (IMRT) is an important tool for cancer treatment. It concentrates high radiation doses in complex target volumes, while sparing the surrounding tissues. IMRT is traditionally performed using Multileaf Collimators (MLC) or Compensator Blocks. The conventional way used to manufacture IMRT compensator blocks, which uses milling machines, is an important drawback over the MLC method, due to high operational and production costs. In this research, we developed a simpler alternative method to manufacture an IMRT compensator block from a fluency map generated by a commercial treatment planning system (TPS). This map was converted into a mold, and then printed using a 3D printer. The final IMRT compensator block was achieved by filling the mold with cerrobend alloy. To validate this method a quality assurance was performed using dosimetric films to compare the measured dose distributions to those predicted by the TPS system. This comparison showed a good agreement among 8 dose profiles from each situation, with a maximum RMS error of 8.84 % for the tested profiles. This suggests that the 3D printers can be effectively used to manufacture IMRT compensator blocks. The main advantage to this approach is that it can be fully conducted inside a radiotherapy facility, which results in lower costs and production times.