3355 - Conception to Development of a First-of-Its-Kind Ultra Compact, Affordable and Ergonomic Scalp Cooling System for Preventing Chemotherapy-Induced Alopecia

Purpose/Objective(s):

Over 1 million new patients undergo chemotherapy treatment annually. About 65% experience chemotherapy-induced alopecia (CIA) as a side effect. Multiple studies show cancer patients describe hair loss as the worst part of treatment. Up to 60% report chronic decreases in self-esteem and body image as a result. Although scalp cooling is an FDA-approved technology up to 90% effective in preventing CIA, studies show only 10% of eligible patients use it due to cost, bulkiness, and limited access. Current devices weigh over 25 lbs, cost $2,000–$4,000, and require specialized clinics, excluding many patients.

We aim to close this gap in supportive care for cancer patients by developing a first-of-its-kind, compact, affordable, and ergonomic scalp cooling system that is less than half the weight, size and price of any currently available device on the market.

Materials/Methods:

A 7-stage comprehensive new product development approach was followed: 1) idea generation, 2) idea screening (feedback from users/past chemotherapy patients and oncologists), 3) concept development and testing (engineering collaboration and industry feedback), 4) market analysis, 5) product development (physical prototype and preliminary testing), 6) market testing, 7) commercialization and product launch (currently in progress).

Results:

A second-pass physical prototype of our proprietary scalp cooling refrigeration system was developed, achieving a 50% reduction in weight (<12 lbs) compared to commercial systems (25–40 lbs) and a >60% reduction in projected cost (<$1,000 vs. $2,000–$4,000) while maintaining a smaller footprint (10x9x6 inches) than any currently available market competitor. Additional human-centered design features include a removable battery, an angled LCD display screen with adjustable temperature and timer, vent guards for patient safety, and an electrically inert coolant solution for safety. Preliminary testing on the refrigeration system shows the device reaches target scalp cooling temperature ranges. Current testing is in progress for sustaining battery and pump durability.

A first-pass physical prototype of our proprietary cooling cap utilizes a thermoplastic polyurethane in a bifilar coolant channel layout for the inner cap and a 3-layer insulated outer cap design composed of spandex, thermal lining, and neoprene. The cap achieves a personalized one-size-fits-all design via a tightening Velcro chin strap and an ergonomic, adjustable sizing wheel secured with one hand in the outer layer. Preliminary testing confirmed watertightness and adequate scalp temperature transfer. Current testing for efficient, evenly distributed scalp temperature is underway.

Conclusion:

We introduce a compact, affordable and ergonomic scalp cooling system designed to prevent chemotherapy-induced alopecia and make supportive care in oncology an accessible reality for all patients. A clinical feasibility study will be launched to evaluate usability, comfort, and efficacy.