Radiation-Free Patient Surface Modeling Using a Hand-Held 3D Scanner for Custom Lead Shield Fabrication
Abstract
Purpose
To eliminate unnecessary radiation exposure and streamline patient-specific lead shield fabrication for skin cancer treatment, this study evaluates the feasibility of generating a 3D patient surface model using a low-cost hand-held 3D scanner. The accuracy of the hand-held scanner–derived model was compared with a conventional CT-based 3D model.
Methods
Topographical mapping of the patient face using optical 3D scanning has been proposed as an alternative to CT imaging to avoid additional radiation exposure and imaging costs. Although a gantry-mounted optical 3D scanner was previously introduced for lead shielding fabrication, CT-based modeling remains in use at our institution. With recent advancements in 3D scanning and printing technology, affordable hand-held scanners are now available. In this study, a hand-held 3D scanner (CR-Scan Ferret, Creality) with a stated accuracy of 0.1 mm and spatial resolution of approximately 0.16 mm was evaluated. A head phantom was scanned using both CT and the hand-held 3D scanner. The optical scan data were processed using CrealityScan software to generate AI-enhanced STL models. MeshMixer (Autodesk) was used for model refinement, preparation for 3D printing, and geometric comparison between CT-derived and optically derived STL models.
Results
Geometric differences between the CT-based and hand-held scanner–based 3D models were minimal. The hand-held 3D scanner demonstrated several advantages over CT-based modeling, including higher surface resolution, comparable accuracy, lower cost, repeatable acquisition, and elimination of auxiliary hardware such as a gantry system. Most importantly, the hand-held scanning approach avoids ionizing radiation exposure to the patient.
Conclusion
Hand-held optical 3D scanning provides a practical, accurate, and radiation-free alternative to CT-based modeling for patient-specific lead shield fabrication in skin cancer treatment.