Background
Electron Cutouts are commonly used in radiation therapy to shape a radiation field that kills malignant cells in the body. These Cutouts are used in both Varian and Elekta Linear Accelerator Systems (LINAC's) and for the most part, are a fantastic solution. Unfortunately, the typical method of manufacturing Cutouts involves pouring low melting point alloy (LMPA) which contains Lead and Cadmium. Both these materials are toxic and pose serious health risks to the clinicians, manufacturers, and anyone within the device supply chain. For the past four years, 3D One has been committed to provide non-toxic, Lead and Cadmium free alternatives. The 3D One Cutout eliminates the need for pouring LMPA in mould rooms and removes the exposure to toxic materials associated with handling traditional Cutouts. The product we stand behind today is the ninth and final iteration, the culmination of considered product development.
The Problem
Low melting Point Alloy cutouts are produced using toxic Lead and cadmium, and the need for a mould room in a clinic to pour cutouts were found to be the issues 3D one needed to solve. These issues were challenging since time was a deciding factor for clinic and achieving a Non-Toxic product with fast turnaround was set as the goal to work towards.
The initial 3D One Cutout was a Tungsten carbide powder, with a binder applied to lock in the top layer, and sealed with epoxy resin. we achieved a product that was both Non-Toxic and could be a patient-specific option for clinics. However, the issue of lead time soon became evident. To improve our manufacturing turnaround time, a revision of our process was needed. Curing time for both the binder and the epoxy was seen to be the limiting factor. Opting for a UV cured epoxy allowed us to achieve faster turnaround times, however, the epoxy was toxic and as a company, we believed that this was not following our core beliefs of producing Non-Toxic products.
The idea of recycling our eCutout eventuated, with the first batch of products returning to us. When we began recycling the first revisions of eCutouts, we were finding, when heating, the binders were altering the pH of the Tungsten Carbide, restricting our yield return too only 60%. This was due to a change in pH that rendered the product unfit according to us. We had a goal of reusing a vast majority of the product to increase turnaround times as well as leverage better pricing agreements for our valued clients.
Revisions
Conversing with some of the leading physicians around Australia, we altered the process of how we print our frames, to not include the aperture printed into the product, but instead, have a sacrificial piece which could be popped out. The 3D printed aperture piece was causing some concern with possible dosimetric issues. The result? A Tungsten carbide Cutout with a precise aperture. With the increasing demand for our eCutouts, a more stringent QC procedure also needed to be put into place. A process was needed where we could cut more accurate apertures at a faster pace in our products. Water Jet cutting was implemented across our line of products and allows ±0.1mm accuracy at great speed. Finally, we were making ground on having a product which can be produced as a Non-toxic replacement for LMPA with a realistic lead time. However, we, 3D One, we were not done yet.
Same Day Dispatch?
Our product today has gone under its biggest challenge yet and that was to reduce the lead time to same day dispatch. This is achieved by using our proven Attenuflex dough, rolling and pressing it, with apertures cut once orders were placed. This has improved our lead time greatly and allows us to provide a top-class product that resembles a work of art compared to previous revisions. We are very happy to produce these as both eCutout library sets or even bespoke pieces.
The Result
Our Latest innovation of eCutouts is something we have worked hard on for almost 4 years with 9 revisions and countless issues both internal and external which we have rectified and persevered through, to now supply a product we are proud of. We believe this to be the best replacement on the market for LMPA cutouts and with fast turnaround and competitive pricing, why wouldn't you want a non-toxic, lead alternative that can be custom cut very precisely?
With a continual improvement mindset, our R&D team work to improve every aspect of our products so that we can be sure we are the leading supplier of Non-Toxic, Lead and Cadmium free Cutouts for both Varian and Elekta Linacs.
