Customized, 3D Printed Breast Prostheses Promise Affordability and Comfort

Aside from skin cancers, breast cancer is the most common type of cancer among women in the United States. In 2025 alone, an estimated 42,170 women are expected to die from the disease. However, ongoing advances in screening, prevention, and treatment continue to offer hope for reducing this number over time. In response to this challenge, researchers at the Carle Illinois College of Medicine—part of the University of Illinois Urbana-Champaign—are utilizing cutting-edge technology to support women who have undergone a mastectomy.

A mastectomy is a surgical procedure that removes one or both breasts to treat or prevent cancer. Using advanced scanning and 3D printing techniques, the team is developing personalized breast prostheses tailored to each patient’s unique anatomy. Their goal is to enable these custom prostheses to be produced directly in a doctor’s office, making them more accessible, faster to obtain, and more affordable than current options.

Rand Kittani (left) and Dr. Victor Stams (right) develop an affordable 3D breast prosthesis (Photo credits: University of Illinois)

3D Printed Breast Prostheses for Accessibility and Comfort

After a mastectomy, some women wear prostheses to restore the shape of the breast under their clothes. These prostheses are often very expensive, custom-made ones. Dr. Victor Stams, plastic surgeon and professor at CI MED, explains that some patients forgo prostheses because they do not have insurance, find the costs too high or are simply unaware of their options. Together with Rand Kittani, an internal medicine student, they are developing a method to manufacture 3D printed prostheses directly on site at a lower cost. According to Rand Kittani, this solution offers a fast and affordable alternative to conventional breast reconstruction, helping to overcome the financial and social barriers that prevent some patients from accessing care. The CI MED team is developing prostheses costing between $50 and $200. Because these are manufactured directly by the doctor, they avoid long delays. “Beyond cost and convenience, what excites me most is the opportunity to give patients a sense of dignity and control during a vulnerable time,” Dr. Victor Stams said.

Julien Montenero, a French anatomist who creates realistic breast prostheses from 3D images of the body, inspired the Illinois team’s work. Using affordable 3D scanners already on the market, they scan the healthy breast to obtain a digital model before the operation. Thanks to this file, they can rapidly manufacture a prosthesis perfectly adapted to each patient. According to Victor Stams, this made-to-measure approach also improves aesthetics, which goes a long way in making the patient feel better after surgery.

Prostheses are often made of silicone or soft materials, and the more customized and realistic they are, the more expensive they will be. The CI MED team tests several materials, such as 3D printed plastic, TPU, and even bioprinting, to find the best option combining comfort, fit and affordability. To learn more about the project, click HERE.

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*Cover Photo Credits: Freepik