RADIATION PHYSICS AND CHEMISTRY, vol.244, 2026 (SCI-Expanded, Scopus)
This study evaluated the dosimetric performance of customized, patient-specific 3D-printed polylactic acid applicators designed for high-dose-rate (HDR) skin brachytherapy and compared them with a standard commercial Leipzig applicator. The mean Hounsfield Unit (HU) of the PLA test slab was-8.63 +/- 12.88, confirming radiological similarity to soft tissue. Optically Stimulated Luminescence dosimeters were employed for quantitative dose verification across all applicator types, and calibration results demonstrated excellent linearity between OSL signal and absorbed dose. At the prescribed 3 Gy reference dose, the Leipzig applicator yielded a mean measured dose of 2.398 Gy, while the 3D Design Applicator delivered 3.953 Gy, and the 3D Mold Applicator achieved 3.136 Gy, representing the closest agreement with the Treatment Planning System reference. These deviations are mainly attributed to the steep dose gradients inherent to HDR brachytherapy, applicator-surface geometry, and detector positioning uncertainties. Both 3D-printed applicators demonstrated improved anatomical conformity to curved surfaces with reduced air gaps. CT imaging verified precise anatomical alignment and mechanical stability of the 3D-printed designs. Overall, patient-specific 3D-printed PLA applicators demonstrate dosimetric feasibility under phantom conditions and offer a reliable, anatomically conformal, and cost-efficient alternative to conventional HDR brachytherapy applicators. In particular, the 3D Mold Applicator showed the closest agreement with TPS-calculated doses, supporting its potential for further clinical investigation.