Three Layer Breast Prosthesis

A breast form prosthesis, comprising:

• (a) four films that are welded together at a single weld to form three chambers having a shape of a breast form footprint, the three chambers including:
• a first chamber, a second chamber and a third chamber;
• (b) an outer first layer disposed in the first chamber and including a first material that has a first firmness, the first layer having a shape corresponding to a shape of a breast form, the first material including a silicone gel with a first concentration of a methyl hydrosiloxane polymer cross-linker;
• (c) a middle second layer disposed adjacent to the first layer in the second chamber and including a second material that has a second firmness that is greater than the first firmness, the second material including a silicone gel with a second concentration, greater than the first concentration, of a methyl hydrosiloxane polymer cross-linker;
• and
• (d) an inner third layer disposed in the third chamber and adjacent to the second layer opposite from the first layer and including a third material that has a third firmness that is less than the second firmness the third material including a silicone gel with a third concentration, less than the second concentration, of a methyl hydrosiloxane polymer cross-linker.

A method of making a breast prosthesis, comprising the steps of:

• (a) welding together four flexible films with a single weld so as to form a breast form envelope, the breast form envelope including a first chamber, a second chamber and a third chamber, each chamber having a shape of a breast form footprint;
• (b) placing the breast form envelope into a mold having a shape that is complementary in shape to a breast form;
• (c) injecting a first material into the first chamber, the first material having a first firmness that allows for a 20 mm to a 25 mm penetration by a cone penetrometer when cured;
• (d) injecting a second material into the second chamber, the second material having a second firmness when cured, the second firmness being greater than the first firmness;
• (e) injecting a third material into the third chamber, the third material having a third firmness when cured, the third firmness being less than the second firmness;
• and
• (f) heating the mold, the breast form envelope, the first material, the second material and the third material to a temperature sufficient to cure the first material to the first firmness, the second material to the second firmness and the third material to the third firmness.