After receiving your scan, our team makes your custom breast form by combining both advanced technology and hand craftsmanship in our production facility.
In the final part of our two-part series on how custom breast forms are made, we explain the fabrication process. After the first step of creating your scan is complete, we then use your scan as a blueprint to produce a handmade, custom breast form that fits your unique size and contour.
Creating a Digital Model
The digital images transmitted to our team from our scanning platform help create 3D imaging that communicates directly to our proprietary fabrication software. This step of the process allows us to align both your chest and your bra scan by using the alignment markers placed on your body as reference points. Once these 3D images are combined, the model is saved as a file that is then electronically sent to our CNC carver thus initiating the fabrication process.
Carving and Molding
The carving process is a specialized computer controlled process that involves intricate calibration, which in turn, allows us to maintain a degree accuracy that is unparalleled in our industry. Remarkably, although this process is very detailed, the entire carving process takes less than 20 minutes.
Once the carving stage is complete, we use a utilize hand craftsmanship to begin the molding process.
During this step of the process the drape, slope and nipple design that you previously chose, in the scanning process, are placed on the 3D carve. Thus allowing the molds we create to accurately depict the personal choices you have selected in the design of your custom form. Once all choices have been verified and placed on the carve, the model is encapsulated and a liquid molding compound is poured over the entire area thus forming a plaster mold that will be used to manufacture the custom form.
Foaming and Fitting
The plaster mold then gets placed into a containment box so a Fit Form can be produced. We use a proprietary 2 part polyurethane foam mixed at a ratio that is designed to blow a dense foam product that will be used to insure the accuracy of the form fit. The foam is initially allowed to cure for 10 minutes. Once the foam is set it can be removed from the mold. It is allowed to cure for 10 additional minutes at a elevated temperature to allow for the complete catalyzation of the foam. When the foam is completely cured it is trimmed to specification, packaged and shipped to you!
The Fit Form is yet another way that we insure the accuracy the fit. The Fit Form product is an exact replication of the size and shape of the final form you helped design.
Next, we will schedule a second appointment in which we will fit you with the Fit Form using the bra you were scanned in to test the accuracy of the fit. Your fitter will consult you on the fit and either confirm the fit with us or request any necessary adjustments to fit you better. Whether the fit is perfect or needs to be altered, your fitter will let our team know so that we can proceed with the final steps of the fabrication process.
Final Fabrication Phases
Once the Fit Form’s fit is confirmed, we then re-verify all of the custom options you have selected in the design of your form. We will also verify the product type you chose (Virage, Profile or Naturel). Depending on the type of form you have chosen, the skin of the breast form is created using a custom pigmented silicone or synthetic latex which is cured into the same customized mold that the Fit Form was created in. The addition of the areola colors are built intrinsically into the form. When the desired skin thickness is achieved (in Virage and Naturel products) a core foam is then created and adhered to the skin. The core foam creates the custom breast form contours of your chest wall thus allowing the form to fit your individual needs.
The back of your custom breast form is made separately (using a proprietary blend of silicone) to insure a soft pliable backing that fits comfortably against your chest wall.
All of ContourMed’s forms are waterproof and are tested extensively in the quality control process to make certain the integrity of the product remains intact for the life of the form. After a final inspection, the final product is shipped to you ready to wear.
For more information about how custom breast forms are made, contact ContourMed at 501-214-6080.