Optical scan and 3D printing guided radiation therapy – an application and provincial experience in cutaneous nasal carcinoma

Background Single field Orthovoltage radiation is an acceptable modality used for the treatment of nasal cutaneous cancer. However, this technique has dosimetric pitfalls and unnecessary excessive exposure of radiation to organs at risk (OAR). We present the clinical outcome of a case series of cutaneous nasal tumours using a novel technique incorporating an optical scanner and a 3-dimensional (3D) printer to deliver treatments using parallel opposed (POP) fields. Materials and methods The POP delivery method was validated using ion chamber and phantom measurements before implementation. A retrospective chart review of 26 patients treated with this technique between 2015 and 2019 was conducted. Patients’ demographics and treatment outcomes were gathered and tabulated. These patients first underwent an optical scan of their faces to collect topographical data. The data were then transcribed into 3D printing algorithms, and positive impressions of the faces were printed. Custom nose block bolus was made with wax encased in an acrylic shell; 4 cm thick using the printed face models. Custom lead shielding was also generated. Treatments were delivered using 250 KeV photons POP arrangement with 4 cm diameter circle applicator cone and prescribed to the midplane. Dose and fractionation were as per physician discretion. Results Phantom measurements at mid-plane were found to match the prescribed dose within ±0.5%. For the 26 cases in this review, the median age was 78.5 years, with 15 females and 11 males. 85% of cases had Basal cell carcinoma (BCC); 1 had squamous cell carcinoma (SCC), one had synchronous BCC + SCC, and 1 had Merkel cell carcinoma. Twenty-one cases had T1N0 disease, 4 had T2N0, and 1 had T3N0. Dose and fractionation delivered were 40Gy in 10 fractions for the majority of cases. The complete response rate at a median follow-up of 6 months was 88%; 1 patient had a refractory tumour, and one patient had a recurrence. Toxicities were minor with 81% with no reported side effects. Three patients experienced grade 3 skin toxicity. Conclusions Utilization of optic scanner and 3D printing technology, with the innovative approach of using POP orthovoltage beams, allows an effective and efficient way of treatment carcinomas of the nose with a high control rate and low toxicity profiles.