Development of Personalized External Breast Prosthesis Prototype Using 3D Modeling in Unilateral Post-Mastectomy Patient

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More than 2,000 women are diagnosed each year with breast cancer in Honduras, and many of them face a mastectomy as the only way to save their lives. For those who do not have access to breast reconstruction, recovery can become even more challenging, as coming to terms with changes in their physical appearance is a significant struggle, especially when the available alternatives are limited and lack personalization. This project arises as a response to that gap, developing a customized external breast prosthesis through 3D modeling and additive manufacturing, with the aim of improving comfort, functionality and aesthetics over conventional prostheses. 3D scanning techniques, biomechanical analysis, clinical interviews and usability testing with a unilateral post-mastectomy patient were employed, resulting in a prosthesis that morphologically adapted to the patient’s body, mimicked the shape of her healthy breast and did not cause sweating. The satisfaction survey conducted after the use of the personalized prosthesis indicated improvements in physical and emotional well-being. Meanwhile, additional questionnaires revealed a lack of access to postoperative psychological support, pointing to the need for more comprehensive recovery approaches. In conclusion, it was validated that the design achieved its overall objective by offering a solution that not only improves the patient’s physical experience, but also brings therapeutic value to the comprehensive post-mastectomy recovery process.

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109-118

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January 2026

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© 2026 Trans Tech Publications Ltd. All Rights Reserved

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