Development of a 3D-printed bra with an incorporated prosthesis for post-mastectomy women

Background: Women who have undergone mastectomy and do not undergo reconstruction often face challenges with existing bras and prostheses. Mismatches between generic prostheses and individual mastectomy cases result in physical and mental discomfort, such as pain, sweating, asymmetry, and concerns about prosthesis movement. Existing solutions are limited in their ability to address these challenges effectively. Objectives: This study aims to develop a workflow for designing and fabricating a lightweight post-mastectomy bra with an incorporated prosthesis to improve fit, symmetry, and comfort. Design: We developed a customization and fabrication workflow based on a three-dimensional (3D) scan and the manipulation of its geometry to achieve fit and symmetry. We leverage the 3D-printed spacer fabric technique to produce a lightweight, breathable structure. Methods: We conducted mechanical tests to determine printing parameters and evaluate the compression properties of the prosthesis and the bra materials. Additionally, we conducted a wear test for 10 women who underwent a mastectomy. A personalized bra was printed for each, and their feedback on fit and comfort was collected weekly over a 3-week test period. Results: The printed bras were lightweight (150–250 g), breathable, and provided improved symmetry. The mechanical tests confirmed comparable softness to silicone prostheses at significantly lower weight. The user study results show that the custom bras offer several advantages, including reduced weight and improved symmetry, though some participants noted mild fit and texture issues. Conclusion: Integrating the prosthesis into a 3D-printed bra offers a promising personalized solution for post-mastectomy women. This approach enhances comfort, symmetry, and emotional well-being, however, further improvements need to be made to improve the material and tactility.